A wall brick and a method for preparing the same

Abstract

The present invention relates to the technical field of building materials, and in particular to a wall brick and a preparation method thereof. The wall brick is prepared from raw materials including the following components by weight: 70-100 parts of water; 30-50 parts of latex; 10-50 parts of cement; 30-50 parts of lime; 10-30 parts of gypsum; 10-30 parts of sand and stone; 10-30 parts of attapulgite; 20-80 parts of hollow glass microspheres; 0.3-0.8 parts of PP fiber; 60-100 parts of crude MDI; and 1-10 parts of catalyst. The hollow glass microspheres are added to the wall bricks without foaming, and micron-level cavities are uniformly distributed in the wall bricks, and the wall bricks prepared have better compressive strength. In addition, the hollow glass microspheres are added to the wall bricks, which not only reduces the weight of the wall bricks, but also improves the thermal insulation performance. The hollow glass microspheres cooperate with other components to form a wall brick with a lower density, better compressive strength, lower water absorption, and better thermal insulation performance.

Description

Technical Field

[0001] The invention relates to the technical field of building materials, and in particular to a wall brick and a preparation method thereof. Background Art

[0002] Aerated bricks are aerated concrete blocks produced by high-temperature autoclaving equipment. Ordinary aerated bricks are made of fly ash, lime, cement, gypsum and other raw materials, with appropriate amounts of gas-generating agents and regulators added, and are a kind of porous concrete product made through processes such as mixing, pouring, static stopping, cutting and high-pressure steaming. Existing aerated bricks use aluminum foaming to reduce the density and thermal conductivity of wall bricks. The foamed aerated bricks have a porous structure inside, a relatively loose structure, low compressive strength, no load-bearing, and a short service life. Because there are cavities inside aerated bricks, the structure is loose, and materials such as lime, cement, and gypsum easily absorb water, resulting in a high water absorption rate of aerated bricks.

[0003] The patent with publication number CN109650823A discloses a high-strength environmentally friendly aerated brick. By adding hollow glass microspheres, the mass of the aerated brick is reduced. At the same time, the hollow glass microspheres have a certain hardness, so that the compressive strength of the aerated brick is not easily affected, and it is also beneficial to enhance the heat insulation and sound insulation effects of the aerated brick. Since the hollow glass microspheres are tiny spheres, the inside of the aerated brick has good fluidity. At the same time, the hollow glass microspheres are isotropic, which is beneficial to eliminate the internal stress of the aerated brick and facilitate the cutting operation of the aerated brick during the molding process, so that the aerated brick and its cut surface are not easy to warp. At the same time, since the surface of the hollow glass microspheres is smooth, the cut surface of the aerated brick is not easy to have burrs. However, the amount of hollow glass microspheres added is very small, and the fundamental reason for weight reduction is still foaming, which cannot improve the water absorption rate of the wall tiles.

[0004] The patent with publication number CN103992091A discloses a lightweight and high-strength aerated brick and a preparation method thereof. By using glass hollow microspheres, fly ash hollow microspheres, and fumed silica, the aerated brick has high strength, good fire resistance, thermal insulation and sound insulation, low drying shrinkage, and greatly reduces the weight of the aerated brick, enhances the seismic performance, and has high building safety performance. However, the problem of water absorption rate is not solved. Summary of the invention

[0005] In view of this, the technical problem to be solved by the present invention is to provide a wall tile and a preparation method thereof. The wall tile provided by the present invention has better compressive strength and lower water absorption rate.

[0006] The present invention provides a wall brick, which is prepared from raw materials including the following components in parts by weight:

[0007]

[0008] Preferably, the latex includes at least one of pure acrylic emulsion, silicone acrylic emulsion and styrene acrylic emulsion.

[0009] Preferably, the cement is Portland cement.

[0010] Preferably, the lime is quicklime;

[0011] The gypsum is plaster of Paris.

[0012] Preferably, the true density of the hollow glass microspheres is 0.12 to 0.70 g / cm 3 , particle size D90 is 5~100μm.

[0013] Preferably, the catalyst comprises a tin catalyst.

[0014] The present invention also provides a method for preparing the wall bricks mentioned above, comprising the following steps:

[0015] A) mixing latex, sand and water to obtain slurry a;

[0016] B) mixing slurry a, cement, lime, gypsum, attapulgite and PP fiber to obtain slurry b;

[0017] C) stirring and mixing the slurry b and the modified hollow glass microspheres to obtain slurry c;

[0018] The modified hollow glass microspheres include hollow glass microspheres and part of crude MDI;

[0019] D) pouring the slurry c into a mold and allowing it to stand for molding to obtain a preform;

[0020] E) spraying a concrete surface treatment agent uniformly onto each surface of the preform, and after drying, obtaining a wall tile;

[0021] The concrete surface treating agent comprises residual crude MDI and a catalyst.

[0022] Preferably, in step A), mixing the latex, sand and water comprises:

[0023] Add water to the stirred mixture of latex and sand and stone, stir and mix, and obtain slurry a; the stirring rate of the mixture of latex and sand and stone is 80-120r / min;

[0024] In step B), the stirring rate of the stirring and mixing is 80 to 120 r / min.

[0025] Preferably, in step C), the stirring rate of the slurry b and the modified hollow glass microspheres is 40 to 60 r / min;

[0026] The preparation method of the modified hollow glass microsphere comprises:

[0027] The hollow glass microspheres and part of the crude MDI were stirred and mixed at 40-60 r / min.

[0028] Preferably, in step D), the static molding time is 10 to 11 hours;

[0029] In step E), the preparation method of the concrete surface treatment agent comprises:

[0030] The remaining crude MDI and catalyst were stirred and mixed at 190-210 r / min.

[0031] The present invention provides a wall brick, which is prepared from raw materials including the following components in parts by weight: 70-100 parts of water; 30-50 parts of latex; 10-50 parts of cement; 30-50 parts of lime; 10-30 parts of gypsum; 10-30 parts of sand and stone; 10-30 parts of attapulgite; 20-80 parts of hollow glass microspheres; 0.3-0.8 parts of PP fiber; 60-100 parts of crude MDI; and 1-10 parts of catalyst. In the present invention, hollow glass microspheres are added to replace aluminum agent foaming, simplify the process, and no hydrogen is released, which reduces safety hazards; at the same time, without the need for foaming, micron-level cavities will be uniformly distributed in the wall bricks, and the compressive strength of the wall bricks prepared is much higher than that of ordinary aerated bricks, and the application range is greatly expanded. In addition, the addition of hollow glass microspheres to the wall bricks not only reduces the weight of the wall bricks, but also improves the thermal insulation performance of the wall bricks. The hollow glass microspheres cooperate with other components to finally obtain wall tiles with low density, high compressive strength, low water absorption and high thermal insulation performance.

[0032] The present invention also provides a method for preparing the wall bricks described above, comprising the following steps: A) mixing latex, sand and water to obtain slurry a; B) mixing slurry a, cement, lime, gypsum, attapulgite and PP fiber to obtain slurry b; C) mixing slurry b and hollow glass microsphere modification to obtain slurry c; the hollow glass microsphere modification includes hollow glass microspheres and part of crude MDI; D) pouring slurry c into a mold, standing and forming, to obtain a preform; E) spraying a concrete surface treatment agent evenly on each surface of the preform, and drying to obtain a wall brick; the concrete surface treatment agent includes remaining crude MDI and a catalyst. The present invention first mixes hollow glass microspheres and a specific amount of crude MDI evenly, and then adds them to cement. On the one hand, the crude MDI has a certain protective effect on the surface of the glass microspheres, so that the glass microspheres are not broken. On the other hand, isocyanate can react with water to generate carbon dioxide gas, further reducing the density of concrete and improving its waterproof performance. The present invention further adopts a specific amount of crude MDI and a catalyst to prepare a concrete surface treatment agent, and the concrete surface treatment agent is evenly sprayed on each surface of the preformed body to improve the waterproof performance and toughness of the wall brick. At the same time, in conjunction with other components, the final obtained wall brick has a lower density, better compressive strength, lower water absorption, and better thermal insulation performance. DETAILED DESCRIPTION

[0033] The technical solution of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0034] The present invention provides a wall brick, which is prepared from raw materials including the following components in parts by weight:

[0035]

[0036] In certain embodiments of the present invention, the latex includes at least one of pure acrylic emulsion, silicone acrylic emulsion, and styrene acrylic emulsion. The solid content of the latex is above 40%. Specifically, it is at least one of RS-3799A, FS-926T, KB-79B, SD-528, ROSF-8806, BC-4206, BC-3208, XG-2000, and BA-201.

[0037] In certain embodiments of the present invention, the cement is silicate cement; specifically P.I or P.II.

[0038] In certain embodiments of the present invention, the lime is quicklime.

[0039] In certain embodiments of the present invention, the gypsum is plaster of Paris.

[0040] In certain embodiments of the present invention, the sand and gravel may be recycled sand and gravel, which may be commonly available on the market.

[0041] In certain embodiments of the present invention, the mass content of attapulgite in the attapulgite is greater than 85%.

[0042] In some embodiments of the present invention, the true density of the hollow glass microspheres is 0.12 to 0.70 g / cm 3 , specifically 0.58~0.62g / cm 3 or 0.40~0.44g / cm 3 The particle size D90 is 5-100 μm, specifically 65 μm or 55 μm; the compressive strength is 4-207 MPa, specifically 83 MPa or 55 MPa. Specifically, the hollow glass microspheres are hollow glass microspheres HL60 or HS42, purchased from Zhengzhou Shenglaite.

[0043] In certain embodiments of the present invention, the mass content of -NCO in the crude MDI is 30.5% to 32.0%. The crude MDI is PAPI, which can be commonly purchased on the market.

[0044] In certain embodiments of the present invention, the length of the PP fiber is 1.5-200.0 mm, specifically 5 mm.

[0045] In certain embodiments of the present invention, the catalyst comprises a tin catalyst; specifically, dibutyltin dilaurate.

[0046] The raw materials for preparing the wall tiles provided by the present invention do not contain a foaming agent, specifically, do not contain an aluminum foaming agent.

[0047] The present invention also provides a method for preparing the wall bricks mentioned above, comprising the following steps:

[0048] A) mixing latex, sand and water to obtain slurry a;

[0049] B) mixing slurry a, cement, lime, gypsum, attapulgite and PP fiber to obtain slurry b;

[0050] C) stirring and mixing the slurry b and the modified hollow glass microspheres to obtain slurry c;

[0051] The modified hollow glass microspheres include hollow glass microspheres and part of crude MDI;

[0052] D) pouring the slurry c into a mold and allowing it to stand for molding to obtain a preform;

[0053] E) spraying a concrete surface treatment agent uniformly onto each surface of the preform, and after drying, obtaining a wall tile;

[0054] The concrete surface treating agent comprises residual crude MDI and a catalyst.

[0055] In step A):

[0056] The latex, sand and water are stirred and mixed to obtain slurry a.

[0057] In certain embodiments of the present invention, mixing latex, sand and water comprises:

[0058] Add water to the stirred mixture of latex and sand and stone, stir and mix well to obtain slurry a.

[0059] The stirring rate of the mixed liquid of latex and sand is 80-120 r / min, specifically 100 r / min.

[0060] In step B):

[0061] The slurry a, cement, lime, gypsum, attapulgite and PP fiber are stirred and mixed to obtain slurry b.

[0062] In certain embodiments of the present invention, the stirring rate of the stirring and mixing is 80-120 r / min, specifically 100 r / min.

[0063] In step C):

[0064] The slurry b and the modified hollow glass microspheres are stirred and mixed to obtain slurry c.

[0065] The modified hollow glass microsphere comprises hollow glass microspheres and part of crude MDI.

[0066] In certain embodiments of the present invention, the method for preparing the modified hollow glass microsphere comprises:

[0067] The hollow glass microspheres and a portion of crude MDI are stirred and mixed at 40 to 60 r / min; specifically, the stirring and mixing rate is 50 r / min.

[0068] In certain embodiments of the present invention, the hollow glass microspheres and a portion of crude MDI are stirred and mixed at 40-60 r / min; specifically, the stirring and mixing rate is 50 r / min.

[0069] In certain embodiments of the present invention, the mass ratio of the hollow glass microspheres to a portion of crude MDI is 95-105:5-15; specifically 100:10.

[0070] In step D):

[0071] The slurry c is poured into a mold and allowed to stand for molding to obtain a preform.

[0072] In certain embodiments of the present invention, the static molding time is 10 to 11 hours, specifically 10 hours.

[0073] In certain embodiments of the present invention, after the static forming, the method further comprises:

[0074] Separate from the mold. After being separated from the mold, it can be put into the cutting machine and cut into the required size.

[0075] In step E):

[0076] The concrete surface treatment agent is evenly sprayed onto each surface of the preformed body, and after drying, a wall tile is obtained;

[0077] The concrete surface treating agent comprises residual crude MDI and a catalyst.

[0078] In some embodiments of the present invention, the spraying thickness is 100 μm to 1 mm; specifically, 100 to 200 μm or 200 to 300 μm.

[0079] In certain embodiments of the present invention, the method for preparing the concrete surface treatment agent comprises:

[0080] The remaining crude MDI and the catalyst are stirred and mixed at 190-210 r / min; specifically, the stirring and mixing rate is 200 r / min.

[0081] The present invention has no particular limitation on the sources of the raw materials used above, and they can be generally commercially available.

[0082] In order to further illustrate the present invention, a wall brick and a preparation method thereof provided by the present invention are described in detail below in conjunction with embodiments, but it should not be construed as limiting the protection scope of the present invention.

[0083] The reagents used in the following examples are all commercially available.

[0084] Example 1

[0085] A wall tile, prepared using raw materials shown in Table 1.

[0086] Table 1 Raw material components and dosage of the wall tiles of Example 1

[0087]

[0088]

[0089] The preparation method of the wall brick comprises:

[0090] 1) adding water to the stirred (100 r / min) mixture of latex and sand, stirring and mixing to obtain slurry a;

[0091] 2) stirring (100 r / min) slurry a, cement, lime, gypsum, attapulgite and PP fiber to obtain slurry b;

[0092] 3) stirring and mixing the hollow glass microspheres and part of the crude MDI at 50 r / min to obtain a modified hollow glass microsphere; the mass ratio of the hollow glass microspheres to part of the crude MDI is 100:10;

[0093] The slurry b and the modified hollow glass microspheres are stirred (50 r / min) to obtain slurry c;

[0094] 4) Pour the slurry c into the mold and let it stand for 10 hours to obtain a preform;

[0095] 5) stirring and mixing the remaining crude MDI and the catalyst at 200 r / min to obtain a concrete surface treatment agent;

[0096] The concrete surface treatment agent is uniformly sprayed (the spraying thickness is 100-200 μm) onto each surface of the preformed body, and after drying, a wall tile is obtained.

[0097] Example 2

[0098] A wall tile, prepared using raw materials shown in Table 2.

[0099] Table 2 Raw material components and dosage of the wall tiles of Example 2

[0100]

[0101]

[0102] The preparation method of the wall brick comprises:

[0103] 1) adding water to the stirred (100 r / min) mixture of latex and sand, stirring and mixing to obtain slurry a;

[0104] 2) stirring (100 r / min) slurry a, cement, lime, gypsum, attapulgite and PP fiber to obtain slurry b;

[0105] 3) stirring and mixing the hollow glass microspheres and part of the crude MDI at 50 r / min to obtain a modified hollow glass microsphere; the mass ratio of the hollow glass microspheres to part of the crude MDI is 100:10;

[0106] The slurry b and the modified hollow glass microspheres are stirred (50 r / min) to obtain slurry c;

[0107] 4) Pour the slurry c into the mold and let it stand for 10 hours to obtain a preform;

[0108] 5) stirring and mixing the remaining crude MDI and the catalyst at 200 r / min to obtain a concrete surface treatment agent;

[0109] The concrete surface treatment agent is uniformly sprayed (the spraying thickness is 200-300 μm) onto each surface of the preformed body, and after drying, a wall tile is obtained.

[0110] Example 3

[0111] A wall tile, prepared using raw materials shown in Table 3.

[0112] Table 3 Raw material components and dosage of the wall tiles of Example 3

[0113]

[0114] The preparation method of the wall brick comprises:

[0115] 1) adding water to the stirred (100 r / min) mixture of latex and sand, stirring and mixing to obtain slurry a;

[0116] 2) stirring (100 r / min) slurry a, cement, lime, gypsum, attapulgite and PP fiber to obtain slurry b;

[0117] 3) stirring and mixing the hollow glass microspheres and part of the crude MDI at 50 r / min to obtain a modified hollow glass microsphere; the mass ratio of the hollow glass microspheres to part of the crude MDI is 100:10;

[0118] The slurry b and the modified hollow glass microspheres are stirred (50 r / min) to obtain slurry c;

[0119] 4) Pour the slurry c into the mold and let it stand for 10 hours to obtain a preform;

[0120] 5) stirring and mixing the remaining crude MDI and the catalyst at 200 r / min to obtain a concrete surface treatment agent;

[0121] The concrete surface treatment agent is uniformly sprayed (the spraying thickness is 200-300 μm) onto each surface of the preformed body, and after drying, a wall tile is obtained.

[0122] Comparative Example 1

[0123] The difference from Example 1 is:

[0124] The slurry b is poured into a mold and allowed to stand for 10 hours to obtain a preformed body; after drying, a wall tile is obtained.

[0125] Comparative Example 2

[0126] Aerated bricks are commercially available as wall bricks.

[0127] Comparative Example 3

[0128] The difference from Example 3 is that:

[0129] In step 3):

[0130] The slurry b and the hollow glass microspheres were stirred (50 r / min) to obtain slurry c; the slurry c was poured into a mold, and after standing for 10 hours, a preform was obtained; after drying, a wall tile was obtained.

[0131] The wall tiles prepared in Examples 1 to 3 and Comparative Examples 1 to 3 were processed into wall tile specimens with a size of 600 mm×200 mm×250 mm. The performance of the wall tile specimens was tested. The results are shown in Table 4.

[0132] Table 4 Performance test results of wall tiles of Examples 1 to 3 and Comparative Examples 1 to 3

[0133]

[0134] It can be seen from Table 4 that the wall bricks provided by the present invention have lower density and thermal conductivity, better compressive strength, and lower water absorption; specifically, the density does not exceed 390kg / m 3 , thermal conductivity does not exceed 0.095W / m·K, compressive strength is not less than 8.0MPa, and water absorption does not exceed 10.1%.

[0135] The above description of the disclosed embodiments enables one skilled in the art to implement or use the present invention. Various modifications to these embodiments will be apparent to one skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention will not be limited to the embodiments shown herein, but rather to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A wall brick is prepared from the following raw materials in parts by weight: The latex is a silicone-acrylic emulsion; The true density of the hollow glass microspheres is 0.12 to 0.70 g / cm 3 , particle size D90 is 5 to 100 μm; The catalyst is dibutyltin dilaurate; The preparation method of the wall brick consists of the following steps: A) mixing latex, sand and water to obtain slurry a; B) mixing slurry a, cement, lime, gypsum, attapulgite and PP fiber to obtain slurry b; C) stirring and mixing the slurry b and the modified hollow glass microspheres to obtain slurry c; The modified hollow glass microspheres include hollow glass microspheres and part of crude MDI; D) pouring the slurry c into a mold and allowing it to stand for molding to obtain a preform; E) spraying a concrete surface treatment agent uniformly onto each surface of the preform, and after drying, obtaining a wall tile; The concrete surface treating agent comprises residual crude MDI and a catalyst.

2. The wall tile according to claim 1, characterized in that: The cement is silicate cement.

3. The wall tile according to claim 1, characterized in that: The lime is quicklime; The gypsum is plaster of Paris.

4. The method for preparing the wall brick according to any one of claims 1 to 3, comprising the following steps: A) mixing latex, sand and water to obtain slurry a; B) mixing slurry a, cement, lime, gypsum, attapulgite and PP fiber to obtain slurry b; C) stirring and mixing the slurry b and the modified hollow glass microspheres to obtain slurry c; The modified hollow glass microspheres include hollow glass microspheres and part of crude MDI; D) pouring the slurry c into a mold and allowing it to stand for molding to obtain a preform; E) spraying a concrete surface treatment agent uniformly onto each surface of the preform, and after drying, obtaining a wall tile; The concrete surface treating agent comprises residual crude MDI and a catalyst.

5. The preparation method according to claim 4, characterized in that: In step A), mixing latex, sand and water comprises: Add water to the stirred mixture of latex and sand and stone, stir and mix, and obtain slurry a; the stirring rate of the mixture of latex and sand and stone is 80-120r / min; In step B), the stirring rate of the stirring and mixing is 80 to 120 r / min.

6. The preparation method according to claim 4, characterized in that: In step C), the stirring rate of the slurry b and the modified hollow glass microspheres is 40 to 60 r / min; The preparation method of the modified hollow glass microsphere comprises: The hollow glass microspheres and part of the crude MDI were stirred and mixed at 40-60 r / min.

7. The preparation method according to claim 4, characterized in that: In step D), the static molding time is 10 to 11 hours; In step E), the preparation method of the concrete surface treatment agent comprises: The remaining crude MDI and catalyst were stirred and mixed at 190-210 r / min.

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