Abstract:
The present invention discloses a fiber reinforcement aerated thermal insulation plate, which is prepared by raw materials having the following weight portions: 80-100 portions of fly ash, 30-50 portions of expanded perlite, 10-20 portions of haydite, 10-20 portions of vegetable fiber, 5-10 portions of winnowing beads, 5-8 portions of sepiolite, 3-5 portions of sodium fluorosilicate, 3-5 portions of calcium formate, 2-4 portions of foaming agent, 0.1-0.5 portion of triisopropanolamine loeate and 0.1-0.3 portion of dimethoxy-ethane. According to the present invention, industrial production wastes are adopted as main raw materials, so that the production cost is reduced; and defects in the existing building thermal insulation plates can be effectively overcome through the cooperation effect produced by organic combination of the fly ash, light aggregates and additives.

Description:
CROSS REFERENCE TO RELATED PATENT APPLICATION 
       [0001]    The present application claims the priority of the Chinese patent application CN 201410235860.3 filed on May 30, 2014. 
       FIELD OF THE INVENTION 
       [0002]    The present invention belongs to the technical field of heat insulating materials for buildings, and in particular, to a fiber reinforcement aerated thermal insulation plate and preparation process thereof. 
       BACKGROUND OF THE INVENTION 
       [0003]    At present, aerated thermal insulation plates commonly used on the building market are easily subjected to such phenomena as cracking, hollowing and even falling off in surface as well as water seepage on wall bodies due to big interior bubbles, high water absorbing capacity, swelling due to damp, drying shrinkage and surface loosening. In addition, the thermal insulation plate has low intensity, high heat conductivity, poor thermal insulation, sound insulation and aerated performances, a polyphenyl stearine foam thermal insulation layer or an insulation layer of other thermal insulation materials must be made on the outer surface of the thermal insulation plate while in use, and thereby bringing such problems as high thermal insulation cost, complex construction, poor thermal insulation layer endurance, large workload for maintenance and inconvenience of secondary decoration. At present, although there are some improvement technologies, the thermal insulation performances are not ideal mostly, and the problems of cracking, loosening and falling off are not solved fundamentally. 
       SUMMARY OF THE INVENTION 
       [0004]    The present invention aims at providing a fiber reinforcement aerated thermal insulation plate and preparation process thereof. According to the preparation process of the present invention, wastes are mainly used as main raw materials, so that the cost of the thermal insulation plate is greatly reduced; moreover, the preparation process has simple steps, and meets the requirements of energy saving and environment protection; the fiber reinforcement aerated thermal insulation plate obtained not only has excellent heat insulation performance, but also has such effects as sound insulation, high intensity, acid-base resistance, corrosion resistance, no deformation, shaking resistance, pressing resistance and light weight, and the like. In order to realize the foregoing objectives, the present invention adopts a technical solution as follows. 
         [0005]    A fiber reinforcement aerated thermal insulation plate is prepared by raw materials having the following weight portions: 
         [0006]    80-100 portions of fly ash, 30-50 portions of expanded perlite, 10-20 portions of haydite, 10-20 portions of vegetable fiber, 5-10 portions of winnowing beads, 5-8 portions of sepiolite, 3-5 portions of sodium fluorosilicate, 3-5 portions of calcium formate, 2-4 portions of foaming agent, 0.1-0.5 portion of triisopropanolamine loeate and 0.1-0.3 portion of dimethoxy-ethane. Preferably, 
         [0007]    The fly ash is grade I or grade II fly ash produced by a power station; 
         [0008]    The haydite is haydite having a bulk density of 450 kg/cm3; 
         [0009]    The vegetable fiber can be one or a mixture of two of wood fiber, hemp palm fiber, coconut fiber, cotton stalk fiber, bamboo fiber and nut shell fiber; 
         [0010]    The winnowing beads are light particle material winnowed from fly ash and filtered by a 80-100 mesh screen; 
         [0011]    The foaming agent adopts scale shaped aluminum powder having high activated aluminum content. 
         [0012]    A preparation process of fiber reinforcement aerated thermal insulation plate comprises the following process steps:
   (1) Preparation:
       a) Removing impurity part of the vegetable fiber raw materials, cutting the vegetable fiber raw materials into 20 cm-30 cm small segments, adopting an air flow type drying machine or a roller type drying machine to dry the vegetable fiber raw materials till moisture of the vegetable fiber raw materials is below 0.1%, and then cutting the vegetable fiber raw materials into 3-5 cm for reserve;   b) Putting the fly ash, expanded perlite, haydite and sepiolite into a pulverizer for pulverization, and then filtering through a 80-100 mesh for reserve;   
       (2) Mixing: putting the fly ash, expanded perlite, haydite, winnowing beads and sepiolite into a stirrer according to the foregoing weight portion proportion firstly, stirring for 5-10 minutes so that the materials are uniformly mixed, then adding the vegetable fiber, sodium fluorosilicate, calcium formate, foaming agent, triisopropanolamine loeate and dimethoxy-ethane in sequence and stirring for 3-5 minutes, after the materials are uniformly mixed, adding proper water to stir for 10-15 minutes, thus obtaining a mixed sizing agent;   (3) Initial set: injecting the mixed sizing agent into a mold, standing and solidifying for 20-50 minutes, thus forming a shaping material;   (4) Shaping: putting the obtained shaping material into a mold for hot pressing and shaping, thus obtaining a plate blank;   (5) Steam-curing: putting the prepared plate blank into a steam-curing chamber, and injecting steams for steam-curing, thus obtaining a plank;   (6) Cutting: cutting the plank after steam-curing according to a size required, thus obtaining a finished product of the fiber reinforcement aerated thermal insulation plate of the present invention.   
 
         [0021]    During shaping in step (4), a shaping temperature is 160° C.-180° C., a shaping pressure is 2 MPa-3 MPa, and a shaping time is 5-10 min. 
         [0022]    During steam-curing in step (5), a steam-curing time is 10-12 h, and an indoor steam-curing temperature is kept at 100-170° C. 
         [0023]    In the fiber reinforcement aerated thermal insulation plate prepared by the present invention, the fly ash and the winnowing beads adopted are wastes produced during industrial production, and the production cost is greatly reduced when the fly ash and the winnowing beads are adopted as base materials. All the expanded perlite, the haydite and the sepiolite are particles having light weight and regular shape, which can sufficiently fill in gaps when being used as aggregates and filled into the thermal insulation plate, greatly improve the thermal insulation performance of the thermal insulation plate, and also largely reduce the specific density of the thermal insulation plate. The vegetable fibers are distributed in the thermal insulation plate disorderly, which not only can avoid cracks, but also can stop crack from spreading, and also greatly improve the intensity of the thermal insulation plate. Aluminum powder used in the present invention is scale shaped powder produced by pure aluminum, having such characteristics as high activated aluminum content, ease dispersion in water, sufficient air emission, convenient and stable use, and the like. During a process of being stirred and mixed with other raw materials for condensation, micropores can be formed inside a wet plank through transpiration of the bubbles, which is beneficial for maintenance of the condensation process, and meanwhile can reduce the volumetric weight of the thermal insulation plate and enhance the thermal insulation performance. 
         [0024]    The present invention has the advantageous effects that:
       1. According to the present invention, industrial production wastes are adopted as main raw materials, so that the production cost is reduced; and defects in the existing building thermal insulation plates can be effectively overcome through the cooperation effect produced by organic combination of the fly ash, light aggregates and additives, and a composite thermal insulation layer is not needed when in use, and crack resistance can be effectively achieved meanwhile.   2. The fiber reinforcement aerated thermal insulation plate obtained by the present invention not only has excellent fire-proof thermal insulation performances, but also has such effects as sound insulation, high intensity, acid-base resistance, corrosion resistance, no deformation, shaking resistance, pressing resistance and light weight, and the like.   3. The fiber reinforcement aerated thermal insulation plate obtained by the present invention can be widely applied to build interior and exterior walls, is convenient to use and construct, can complete architectural construction, thermal insulation and fire-proof procedures at a time, and omits a composite wall surface thermal insulation procedure. Meanwhile, the plate is easy to process, which brings great convenience for pipeline burying and installing as well as secondary decoration.       
 
     
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0028]    A fiber reinforcement aerated thermal insulation plate of the present invention is prepared by raw materials having the following weight portions: 80-100 portions of fly ash, 30-50 portions of expanded perlite, 10-20 portions of haydite, 10-20 portions of vegetable fiber, 5-10 portions of winnowing beads, 5-8 portions of sepiolite, 3-5 portions of sodium fluorosilicate, 3-5 portions of calcium formate, 2-4 portions of foaming agent, 0.1-0.5 portion of triisopropanolamine loeate and 0.1-0.3 portion of dimethoxy-ethane. Preferably, 
         [0029]    The fly ash is grade I or grade II fly ash produced by a power station; 
         [0030]    The haydite is haydite having a bulk density of 450 kg/cm3; 
         [0031]    the vegetable fiber can be one or a mixture of two of wood fiber, hemp palm fiber, coconut fiber, cotton stalk fiber, bamboo fiber and nut shell fiber; 
         [0032]    The winnowing beads are light particle material winnowed from fly ash and filtered by a 80-100 mesh screen; 
         [0033]    The foaming agent adopts scale shaped aluminum powder having high activated aluminum content. 
         [0034]    The preparation process of the fiber reinforcement aerated thermal insulation plate comprises the following process steps:
   (1) Preparation:
       a) removing impurity part of the vegetable fiber raw materials, cutting the vegetable fiber raw materials into 20 cm-30 cm small segments, adopting an air flow type drying machine or a roller type drying machine to dry the vegetable fiber raw materials till moisture of the vegetable fiber raw materials is below 0.1%, and then cutting the vegetable fiber raw materials into 3-5 cm for reserve;   b) putting the fly ash, expanded perlite, haydite and sepiolite into a pulverizer for pulverization, and then filtering through a 80-100 mesh for reserve;   
       (2) Mixing: putting the fly ash, expanded perlite, haydite, winnowing beads and sepiolite into a stirrer according to the foregoing weight portion proportion firstly, stirring for 5-10 minutes so that the materials are uniformly mixed, then adding the vegetable fiber, sodium fluorosilicate, calcium formate, foaming agent, triisopropanolamine loeate and dimethoxy-ethane in sequence and stirring for 3-5 minutes, after the materials are uniformly mixed, adding proper water to stir for 10-15 minutes, thus obtaining a mixed sizing agent;   (3) Initial set: injecting the mixed sizing agent into a mold, standing and solidifying for 20-50 minutes, thus forming a shaping material;   (4) Shaping: putting the obtained shaping material into a mold for hot pressing and shaping, thus obtaining a plate blank;   (5) Steam-curing: putting the prepared plate blank into a steam-curing chamber, and injecting steams for steam-curing, thus obtaining a plank;   (6) Cutting: cutting the plank after steam-curing according to a size required, thus obtaining a finished product of the fiber reinforcement aerated thermal insulation plate of the present invention.   
 
         [0043]    During shaping in step (4), a shaping temperature is 160° C.-180° C., a shaping pressure is 2 MPa-3 MPa, and a shaping time is 5-10 min. 
         [0044]    During steam-curing in step (5), a steam-curing time is 10-12 h, and an indoor steam-curing temperature is kept at 100-170° C. 
       Embodiment 1 
       [0045]    A preparation process of fiber reinforcement aerated thermal insulation plate comprises the following process steps: 
         [0046]    Weighing the raw materials according to the following weight portion proportion: 80 kg fly ash, 30 kg expanded perlite, 10 kg haydite, 10 kg vegetable fiber, 5 kg winnowing beads, 5 kg sepiolite, 3 kg sodium fluorosilicate, 3 kg calcium formate, 2 kg foaming agent, 0.1 kg triisopropanolamine loeate and 0.1 kg dimethoxy-ethane;
       a) Removing impurity part of the vegetable fiber raw materials, cutting the vegetable fiber raw materials into 20 cm small segments, adopting an air flow type drying machine to dry the vegetable fiber raw materials till moisture of the vegetable fiber raw materials is below 0.1%, and then cutting the vegetable fiber raw materials into 3 cm for reserve;   b) Putting the fly ash, expanded perlite, haydite and sepiolite into a pulverizer for pulverization, and then filtering through a 100 mesh for reserve;       (2) Mixing: putting the fly ash, expanded perlite, haydite, winnowing beads and sepiolite into a stirrer according to the foregoing weight portion proportion firstly, stirring for 5 minutes so that the materials are uniformly mixed, then adding the vegetable fiber, sodium fluorosilicate, calcium formate, foaming agent, triisopropanolamine loeate and dimethoxy-ethane in sequence and stirring for 3 minutes, after the materials are uniformly mixed, adding proper water to stir for 10 minutes, thus obtaining a mixed sizing agent;   (3) Initial set: injecting the mixed sizing agent into a mold, standing and solidifying for 20 minutes, thus forming a shaping material;   (4) Shaping: putting the obtained shaping material into a mold for hot pressing and shaping, thus obtaining a plate blank, wherein a shaping temperature is 160° C., a shaping pressure is 2 MPa, and a shaping time is 5 min;   (5) Steam-curing: putting the prepared plate blank into a steam-curing chamber, and injecting steams for steam-curing, thus obtaining a plank, wherein a steam-curing time is 10-12 h, and an indoor steam-curing temperature is kept at 100-170° C.;.   (6) Cutting: cutting the plank after steam-curing according to a size required, thus obtaining a finished product of the fiber reinforcement aerated thermal insulation plate of the present invention.   
 
       Embodiment 2 
       [0054]    A preparation process of fiber reinforcement aerated thermal insulation plate comprises the following process steps: 
         [0055]    Weighing the raw materials according to the following weight portion proportion: 
         [0056]    1000 kg fly ash, 50 kg expanded perlite, 20 kg haydite, 20 kg vegetable fiber, 10 kg winnowing beads, 8 kg sepiolite, 5 kg sodium fluorosilicate, 5 kg calcium formate, 4 kg foaming agent, 0.5 kg triisopropanolamine loeate and 0.3 kg dimethoxy-ethane;
       a) Removing impurity part of the vegetable fiber raw materials, cutting the vegetable fiber raw materials into 30 cm small segments, adopting an air flow type drying machine to dry the vegetable fiber raw materials till moisture of the vegetable fiber raw materials is below 0.1%, and then cutting the vegetable fiber raw materials into 5 cm for reserve;   b) Putting the fly ash, expanded perlite, haydite and sepiolite into a pulverizer for pulverization, and then filtering through a 80 mesh for reserve;       (2) Mixing: putting the fly ash, expanded perlite, haydite, winnowing beads and sepiolite into a stirrer according to the foregoing weight portion proportion firstly, stirring for 10 minutes so that the materials are uniformly mixed, then adding the vegetable fiber, sodium fluorosilicate, calcium formate, foaming agent, triisopropanolamine loeate and dimethoxy-ethane in sequence and stirring for 5 minutes, after the materials are uniformly mixed, adding proper water to stir for 15 minutes, thus obtaining a mixed sizing agent;   (3) Initial set: injecting the mixed sizing agent into a mold, standing and solidifying for 50 minutes, thus forming a shaping material;   (4) Shaping: putting the obtained shaping material into a mold for hot pressing and shaping, thus obtaining a plate blank, wherein a shaping temperature is 180° C., a shaping pressure is 3 MPa, and a shaping time is 10 min;   (5) Steam-curing: putting the prepared plate blank into a steam-curing chamber, and injecting steams for steam-curing, thus obtaining a plank, wherein a steam-curing time is 12 h, and an indoor steam-curing temperature is kept at 170° C.;   (6) Cutting: cutting the plank after steam-curing according to a size required, thus obtaining a finished product of the fiber reinforcement aerated thermal insulation plate of the present invention.   
 
       Embodiment 3  
       [0064]    A preparation process of fiber reinforcement aerated thermal insulation plate comprises the following process steps: 
         [0065]    Weighing the raw materials according to the following weight portion proportion: 
         [0066]    90 kg fly ash, 40 kg expanded perlite, 15 kg haydite, 15 kg vegetable fiber, 8 kg winnowing beads, 8 kg sepiolite, 4 kg sodium fluorosilicate, 4 kg calcium formate, 3 kg foaming agent, 0.3 kg triisopropanolamine loeate and 0.2 kg dimethoxy-ethane;
       a) Removing impurity part of the vegetable fiber raw materials, cutting the vegetable fiber raw materials into 25cm small segments, adopting an air flow type drying machine to dry the vegetable fiber raw materials till moisture of the vegetable fiber raw materials is below 0.1%, and then cutting the vegetable fiber raw materials into 4 cm for reserve;   b) Putting the fly ash, expanded perlite, haydite and sepiolite into a pulverizer for pulverization, and then filtering through a 90 mesh for reserve;       (2) Mixing: putting the fly ash, expanded perlite, haydite, winnowing beads and sepiolite into a stirrer according to the foregoing weight portion proportion firstly, stirring for 8 minutes so that the materials are uniformly mixed, then adding the vegetable fiber, sodium fluorosilicate, calcium formate, foaming agent, triisopropanolamine loeate and dimethoxy-ethane in sequence and stirring for 4 minutes, after the materials are uniformly mixed, adding proper water to stir for 12 minutes, thus obtaining a mixed sizing agent;   (3) Initial set: injecting the mixed sizing agent into a mold, standing and solidifying for 30 minutes, thus forming a shaping material;   (4) Shaping: putting the obtained shaping material into a mold for hot pressing and shaping, thus obtaining a plate blank, wherein a shaping temperature is 170° C., a shaping pressure is 2.5 MPa, and a shaping time is 7 min;   (5) Steam-curing: putting the prepared plate blank into a steam-curing chamber, and injecting steams for steam-curing, thus obtaining a plank, wherein a steam-curing time is 11 h, and an indoor steam-curing temperature is kept at 150° C.;   (6) Cutting: cutting the plank after steam-curing according to a size required, thus obtaining a finished product of the fiber reinforcement aerated thermal insulation plate of the present invention.   
 
         [0074]    The foregoing is merely preferred embodiments of the present invention, but is not intended to limit the right scope of the present invention. It should be pointed out that any modification or equivalent replacement on the technical solution of the present invention made by a person having ordinary skill in the art shall not depart from the protection scope of the present invention.