Core foamed concrete insulation block and its production process

Abstract

The application discloses a kind of core foamed concrete thermal insulation block and production process thereof, belong to building material technical field.The shell and core material are included, the core material is filled in the shell;The core material includes the following raw materials: cement, fly ash, glass cellulose, foaming agent, foam stabilizer, water reducing agent, slag powder, polypropylene fiber, illite powder, porous aggregate, sodium dodecyl benzene sulfonate, cellulose graft methyl methacrylate, hydrogen peroxide, water.The application is by reasonably controlling the dosage ratio of polypropylene fiber, porous aggregate, sodium dodecyl benzene sulfonate, cellulose graft methyl methacrylate (4-6) : (5-13) : (0.3-1) : (0.2-0.8), and then synergistically improves the compressive strength and thermal insulation effect of core foamed concrete thermal insulation block.

Description

Technical Field

[0001] This invention belongs to the field of building materials technology, specifically relating to a core-foamed concrete insulation block and its production process. Background Technology

[0002] With the promotion of building energy conservation and the increasing demand for comfortable living environments, thermal insulation materials are receiving more and more attention. Existing thermal insulation composite bricks or blocks mainly come in various forms, including those with embedded insulation materials, insulation interlayers, or insulation holes and grooves. As one of the building insulation materials, room-temperature non-fired foamed bricks are becoming increasingly popular due to their superior insulation, sound insulation, fire resistance, and strength compared to traditional insulation materials. However, existing foamed bricks on the market have drawbacks such as poor impact resistance and relatively poor durability.

[0003] Chinese patent document "Core-Foamed Concrete Insulating Brick and Preparation Method Thereof" (patent application number: CN201410520874.X) discloses a core-foamed concrete insulating brick, comprising a hollow brick as the outer shell and a cement foaming material filling the cavity of the brick. By weight, the cement foaming material comprises: 30-40 parts cement, 1-2 parts water-reducing agent, 1-2 parts calcium chloride, 0.5-1 part aluminum sulfate, 0.1-1 part foam stabilizer, 20-25 parts hydrogen peroxide, 1-2 parts sodium sulfate, and 150-200 parts water. The insulating brick of this invention has its cement foaming material and the hollow brick body well solidified and bonded together, ensuring a strong and lasting bond and durability. Although the above-mentioned insulating brick has good insulation effect, its compressive strength is not high, which greatly limits its development in the energy-saving building materials industry. How to ensure that thermal insulation bricks have good thermal insulation properties while also having excellent compressive strength is one of the problems that the industry urgently needs to solve. Summary of the Invention

[0004] The purpose of this invention is to provide a core-foamed concrete insulation block and its production process to solve the problem of how to improve the thermal insulation and compressive strength of core-foamed concrete insulation blocks.

[0005] To solve the above technical problems, the present invention adopts the following technical solution:

[0006] A core-filled foamed concrete insulation block includes a shell and a core material, wherein the core material is filled inside the shell; the core material comprises the following raw materials in parts by weight: cement, fly ash, glass cellulose, foaming agent, foam stabilizer, water-reducing agent, slag powder, polypropylene fiber, illite powder, porous aggregate, sodium dodecylbenzene sulfonate, cellulose-grafted methyl methacrylate, hydrogen peroxide, and water; the ratio of polypropylene fiber, porous aggregate, sodium dodecylbenzene sulfonate, and cellulose-grafted methyl methacrylate is (4-6):(5-13):(0.3-1):(0.2-0.8).

[0007] Preferably, the core material comprises the following raw materials in parts by weight: 350-400 parts cement, 20-40 parts fly ash, 2-8 parts glass cellulose, 0.1-1 parts foaming agent, 0.2-0.8 parts foam stabilizer, 0.5-1.5 parts water-reducing agent, 15-30 parts slag powder, 4-6 parts polypropylene fiber, 10-25 parts illite powder, 5-13 parts porous aggregate, 0.3-1 parts sodium dodecylbenzenesulfonate, 0.2-0.8 parts cellulose-grafted methyl methacrylate, 25-35 parts hydrogen peroxide, and 40-60 parts water.

[0008] Preferably, the core material comprises the following raw materials in parts by weight: 380 parts cement, 30 parts fly ash, 6 parts glass cellulose, 0.5 parts foaming agent, 0.7 parts foam stabilizer, 1 part water-reducing agent, 25 parts slag powder, 5 parts polypropylene fiber, 20 parts illite powder, 8 parts porous aggregate, 0.7 parts sodium dodecylbenzene sulfonate, 0.6 parts cellulose-grafted methyl methacrylate, 30 parts hydrogen peroxide, and 50 parts water.

[0009] Preferably, the porous aggregate includes one or more of limestone, perlite, and expanded perlite.

[0010] Preferably, the foaming agent is one of sodium fatty alcohol polyoxyethylene ether sulfate or sodium dodecyl sulfate.

[0011] Preferably, the foam stabilizer is one of sodium stearate or silicone amide.

[0012] Preferably, the water-reducing agent is a naphthalene sulfonate formaldehyde condensate.

[0013] This invention also provides a production process for core-foamed concrete insulation blocks, comprising the following steps:

[0014] (1) Preparation of hollow bricks;

[0015] (2) Preparation of cement foaming materials;

[0016] a. Add fly ash, slag powder, illite powder, and porous aggregate to a mixer for mixing, then pulverize to prepare a composite powder;

[0017] b. Mix cement and water in proportion at a speed of 40-50 rpm until homogeneous, then add composite powder, glass cellulose and polypropylene fiber and mix until homogeneous to form the initial slurry;

[0018] c. Prepare a foaming liquid by mixing foaming agent, foam stabilizer, water reducing agent, sodium dodecylbenzene sulfonate, cellulose-grafted methyl methacrylate and hydrogen peroxide in parts by weight.

[0019] d. Add the foam liquid obtained in step c to the initial slurry obtained in step b, and stir evenly to obtain cement foaming material;

[0020] (3) Fill the cavity of the hollow brick obtained in step (1) with cement foam material and cure it at room temperature until it is completely hardened.

[0021] Preferably, the particle size of the composite powder in step (2) is 8-12 micrometers.

[0022] Preferably, when the hollow bricks are filled with cement foaming material, the moisture content of the hollow bricks is 40%-60%.

[0023] The present invention has the following beneficial effects:

[0024] The patent document cited in the background technology, "Core-Foamed Concrete Insulating Brick and its Preparation Method (Patent Application No.: CN201410520874.X)," includes a hollow brick as the outer shell and a cement foaming material filling the cavity of the brick. By weight, the cement foaming material comprises: 30-40 parts cement, 1-2 parts water-reducing agent, 1-2 parts calcium chloride, 0.5-1 part aluminum sulfate, 0.1-1 part foam stabilizer, 20-25 parts hydrogen peroxide, 1-2 parts sodium sulfate, and 150-200 parts water. The insulating brick of this invention has its cement foaming material and the hollow brick body well solidified and bonded together, ensuring a strong and lasting bond and durability. Although the above-mentioned insulating brick has good thermal insulation effect, its compressive strength is not high, which greatly limits its development in the energy-saving building materials industry. To address the aforementioned technical problems, this invention further optimizes and improves the raw materials. Through numerous experiments, it was discovered that the addition of polypropylene fibers, porous aggregates, sodium dodecylbenzene sulfonate, and cellulose-grafted methyl methacrylate to the raw materials has a synergistic effect. This is because: Adding polypropylene fibers to concrete allows them to easily and rapidly disperse evenly, forming a randomized support system that disperses the directional stress of the concrete, improves its toughness, and extends its service life. Furthermore, the inherent strength of polypropylene fibers, when evenly dispersed in the concrete, creates an anchoring effect, increasing the concrete's strength. Porous aggregates, with their high porosity, low bulk density, and low thermal conductivity, effectively block heat transfer, reducing the equivalent thermal conductivity and thus improving the insulation effect of the concrete. Adding sodium dodecylbenzenesulfonate to cement increases the viscosity of concrete, making it easier to plastically deform and fill small voids, thus improving the density and strength of the concrete. Due to its excellent dispersibility, sodium dodecylbenzenesulfonate effectively reduces the attraction between cement particles and decreases their adhesion, thereby improving the dispersion state of the cement particles and making them more stable. Cellulose-grafted methyl methacrylate (MDMA) is a six-membered ring structure of cellulose that easily combines with polypropylene fibers, acting as a surface modifier. When added to concrete, it can be uniformly dispersed in cement and porous aggregates, filling material voids, forming a mesh structure, and improving the strength of the concrete. This achieves the goal of improving the compressive strength and insulation effect of core-core foamed concrete insulation blocks, solving the technical problems mentioned in the background document and producing unexpected results. Detailed Implementation

[0025] To better understand the present invention, the following embodiments are used for illustration. These embodiments are within the scope of protection of the present invention, but do not limit the scope of protection of the present invention.

[0026] The following embodiments describe a core-filled foamed concrete insulation block, comprising a shell and a core material, wherein the core material is filled within the shell; the core material comprises the following raw materials in parts by weight: 350-400 parts cement, 20-40 parts fly ash, 2-8 parts glass cellulose, 0.1-1 parts foaming agent, 0.2-0.8 parts foam stabilizer, 0.5-1.5 parts water-reducing agent, 15-30 parts slag powder, 4-6 parts polypropylene fiber, 10-25 parts illite powder, 5-13 parts porous aggregate, 0.3-1 parts sodium dodecylbenzenesulfonate, 0.2-0.8 parts cellulose-grafted methyl methacrylate, 25-35 parts hydrogen peroxide, and 40-60 parts water.

[0027] The porous aggregate includes one or more of limestone, perlite, and expanded perlite.

[0028] The foaming agent is one of sodium fatty alcohol polyoxyethylene ether sulfate or sodium dodecyl sulfate.

[0029] The foam stabilizer is either sodium stearate or silicone amide.

[0030] The water-reducing agent is a naphthalene sulfonate formaldehyde condensate.

[0031] A production process for core-foamed concrete insulation blocks includes the following steps:

[0032] (1) Preparation of hollow bricks;

[0033] (2) Preparation of cement foaming materials;

[0034] a. Add fly ash, slag powder, illite powder, and porous aggregate to a mixer for mixing, then crush them to prepare a composite powder with a particle size of 8-12 micrometers;

[0035] b. Mix cement and water in proportion at a speed of 40-50 rpm until homogeneous, then add composite powder, glass cellulose and polypropylene fiber and mix until homogeneous to form the initial slurry;

[0036] c. Prepare a foaming liquid by mixing foaming agent, foam stabilizer, water reducing agent, sodium dodecylbenzene sulfonate, cellulose-grafted methyl methacrylate and hydrogen peroxide in parts by weight.

[0037] d. Add the foam liquid obtained in step c to the initial slurry obtained in step b, and stir evenly to obtain cement foaming material;

[0038] (3) Fill the cavity of the hollow brick with a humidity of 40%-60% obtained in step (1) with cement foam material and cure it at room temperature until it is completely hardened.

[0039] The following describes the process through more specific embodiments.

[0040] Example 1

[0041] A core-filled foamed concrete insulation block includes a shell and a core material, wherein the core material is filled inside the shell; the core material comprises the following raw materials in parts by weight: 375 parts cement, 40 parts fly ash, 8 parts glass cellulose, 0.1 parts foaming agent, 0.4 parts foam stabilizer, 1.5 parts water-reducing agent, 30 parts slag powder, 5 parts polypropylene fiber, 25 parts illite powder, 5 parts porous aggregate, 0.7 parts sodium dodecylbenzenesulfonate, 0.2 parts cellulose-grafted methyl methacrylate, 35 parts hydrogen peroxide, and 55 parts water.

[0042] A production process for core-foamed concrete insulation blocks includes the following steps:

[0043] (1) Preparation of hollow bricks;

[0044] (2) Preparation of cement foaming materials;

[0045] a. Add fly ash, slag powder, illite powder, and porous aggregate to a mixer for mixing, then pulverize to prepare a composite powder with a particle size of 12 micrometers;

[0046] b. Mix cement and water in proportion at a speed of 40 rpm until homogeneous, then add composite powder, glass cellulose and polypropylene fiber and mix until homogeneous to form the initial slurry;

[0047] c. Prepare a foaming liquid by mixing foaming agent, foam stabilizer, water reducing agent, sodium dodecylbenzene sulfonate, cellulose-grafted methyl methacrylate and hydrogen peroxide in parts by weight.

[0048] d. Add the foam liquid obtained in step c to the initial slurry obtained in step b, and stir evenly to obtain cement foaming material;

[0049] (3) Fill the cavity of the hollow brick with a humidity of 55% obtained in step (1) with cement foam material and cure it at room temperature until it is completely hardened.

[0050] Example 2

[0051] A core-filled foamed concrete insulation block includes a shell and a core material, wherein the core material is filled inside the shell; the core material comprises the following raw materials in parts by weight: 380 parts cement, 30 parts fly ash, 6 parts glass cellulose, 0.5 parts foaming agent, 0.7 parts foam stabilizer, 1 part water-reducing agent, 25 parts slag powder, 5 parts polypropylene fiber, 20 parts illite powder, 8 parts porous aggregate, 0.7 parts sodium dodecylbenzenesulfonate, 0.6 parts cellulose-grafted methyl methacrylate, 30 parts hydrogen peroxide, and 50 parts water.

[0052] A production process for core-foamed concrete insulation blocks includes the following steps:

[0053] (1) Preparation of hollow bricks;

[0054] (2) Preparation of cement foaming materials;

[0055] a. Add fly ash, slag powder, illite powder, and porous aggregate to a mixer for mixing, then pulverize to prepare a composite powder with a particle size of 10 micrometers;

[0056] b. Mix cement and water in proportion at a speed of 45 rpm until homogeneous, then add composite powder, glass cellulose and polypropylene fiber and mix until homogeneous to form the initial slurry;

[0057] c. Prepare a foaming liquid by mixing foaming agent, foam stabilizer, water reducing agent, sodium dodecylbenzene sulfonate, cellulose-grafted methyl methacrylate and hydrogen peroxide in parts by weight.

[0058] d. Add the foam liquid obtained in step c to the initial slurry obtained in step b, and stir evenly to obtain cement foaming material;

[0059] (3) Fill the cavity of the hollow brick with a humidity of 50% obtained in step (1) with cement foam material and cure it at room temperature until it is completely hardened.

[0060] Example 3

[0061] A core-foamed concrete insulation block includes a shell and a core material, wherein the core material is filled inside the shell; the core material comprises the following raw materials in parts by weight: 400 parts cement, 20 parts fly ash, 2 parts glass cellulose, 0.8 parts foaming agent, 0.8 parts foam stabilizer, 0.5 parts water-reducing agent, 15 parts slag powder, 6 parts polypropylene fiber, 10 parts illite powder, 9 parts porous aggregate, 1 part sodium dodecylbenzenesulfonate, 0.5 parts cellulose-grafted methyl methacrylate, 25 parts hydrogen peroxide, and 60 parts water.

[0062] A production process for core-foamed concrete insulation blocks includes the following steps:

[0063] (1) Preparation of hollow bricks;

[0064] (2) Preparation of cement foaming materials;

[0065] a. Add fly ash, slag powder, illite powder, and porous aggregate to a mixer for mixing, then pulverize to prepare a composite powder with a particle size of 8 micrometers;

[0066] b. Mix cement and water in proportion at a speed of 45 rpm until homogeneous, then add composite powder, glass cellulose and polypropylene fiber and mix until homogeneous to form the initial slurry;

[0067] c. Prepare a foaming liquid by mixing foaming agent, foam stabilizer, water reducing agent, sodium dodecylbenzene sulfonate, cellulose-grafted methyl methacrylate and hydrogen peroxide in parts by weight.

[0068] d. Add the foam liquid obtained in step c to the initial slurry obtained in step b, and stir evenly to obtain cement foaming material;

[0069] (3) Fill the cavity of the hollow brick with a humidity of 60% obtained in step (1) with cement foam material and cure it at room temperature until it is completely hardened.

[0070] Comparative Example 1

[0071] The production process is basically the same as that in Example 2, except that polypropylene fiber, porous aggregate, sodium dodecylbenzene sulfonate, and cellulose-grafted methyl methacrylate are not added to the raw materials for preparing the core foamed concrete insulation blocks.

[0072] Comparative Example 2

[0073] The production process is basically the same as that in Example 2, except that polypropylene fibers are not added to the raw materials for preparing the core foamed concrete insulation blocks.

[0074] Comparative Example 3

[0075] The production process is basically the same as that in Example 2, except that porous aggregates are not added to the raw materials for preparing core-foamed concrete insulation blocks.

[0076] Comparative Example 4

[0077] The production process is basically the same as that in Example 2, except that sodium dodecylbenzenesulfonate is not added to the raw materials for preparing the core foamed concrete insulation blocks.

[0078] Comparative Example 5

[0079] The production process is basically the same as that in Example 2, except that cellulose grafted methyl methacrylate is not added to the raw materials for preparing the core foamed concrete insulation blocks.

[0080] Comparative Example 6

[0081] Core-foamed concrete insulation bricks were prepared using the method described in Example 1 of the Chinese patent document "Core-foamed concrete insulation bricks and their preparation method (patent application number: CN201410520874.X)".

[0082] Foamed concrete blocks were prepared according to the methods of Examples 1-3 and Comparative Examples 1-6, and their compressive strength was tested in accordance with the national standard GB / T11969-2020 "Test Method for Performance of Autoclaved Aerated Concrete".

[0083] The equivalent thermal conductivity was determined using a thermal conductivity meter according to GB / T32981-2016, "Method for Determination of Equivalent Thermal Conductivity of Wall Materials". The results are shown in the table below.

[0084]

[0085]

[0086] As can be seen from the table above: (1) As can be seen from the data of Examples 1-3, the core foamed concrete insulation block prepared by the present invention has excellent compressive strength and insulation effect.

[0087] (2) By testing the compressive strength and equivalent thermal conductivity of the core-foamed concrete insulation blocks, it was found that the compressive strength and insulation effect of the insulation blocks in Example 2 were higher than those in Comparative Examples 1-5. This indicates that the polypropylene fiber, porous aggregate, sodium dodecylbenzene sulfonate, and cellulose-grafted methyl methacrylate in the raw materials synergistically improved the compressive strength and insulation effect of the core-foamed concrete insulation blocks. This is because:

[0088] Adding polypropylene fibers to concrete allows them to disperse easily, quickly, and evenly, forming a randomized support system. This disperses the directional stress in the concrete, improves its toughness, and extends its service life. Furthermore, the inherent strength of the polypropylene fibers, when evenly dispersed, creates an anchoring effect, enhancing the concrete's strength. Porous aggregates, with their high porosity, low bulk density, and low thermal conductivity, effectively block heat transfer and reduce the equivalent thermal conductivity, thus improving the insulation effect of concrete. Adding sodium dodecylbenzene sulfonate to cement increases the viscosity of concrete, making it easier to plastically deform and fill small voids, thus improving its density and strength. Due to its excellent dispersibility, sodium dodecylbenzene sulfonate effectively reduces the attraction and adhesion between cement particles, improving their dispersion and stability. Cellulose-grafted methyl methacrylate is a six-membered ring structure of cellulose that easily combines with polypropylene fibers to act as a surface modifier. When added to concrete, it can be evenly dispersed in cement and porous aggregates, filling material voids, forming a mesh structure, improving the strength and mechanical properties of concrete.

[0089] (3) As can be seen from the data of Examples 1-3 and Comparative Example 6, the compressive strength of the core foamed concrete insulation block measured in Examples 1-3 is significantly higher than that of the insulation block measured in Comparative Example 6 (Prior Art); the equivalent thermal conductivity of the core foamed concrete insulation block measured in Examples 1-3 is significantly lower than that of the insulation block measured in Comparative Example 6 (Prior Art), highlighting the significant progress of the present invention.

[0090] The above content should not be construed as limiting the specific implementation of this invention to these descriptions. For those skilled in the art, several simple deductions or substitutions can be made without departing from the concept of this invention, and all such deductions or substitutions should be considered as falling within the patent protection scope defined by the submitted claims.

Claims

1. A core-foam concrete insulation block, characterized by, The product comprises a shell and a core material, wherein the core material is filled within the shell. The core material comprises the following raw materials in parts by weight: 350-400 parts cement, 20-40 parts fly ash, 2-8 parts glass fiber, 0.1-1 parts foaming agent, 0.2-0.8 parts foam stabilizer, 0.5-1.5 parts water-reducing agent, 15-30 parts slag powder, 4-6 parts polypropylene fiber, 10-25 parts illite powder, 5-13 parts porous aggregate, 0.3-1 parts sodium dodecylbenzenesulfonate, 0.2-0.8 parts cellulose-grafted methyl methacrylate, 25-35 parts hydrogen peroxide, and 40-60 parts water. The porous aggregate includes one or more of limestone and perlite; The foaming agent is one of sodium fatty alcohol polyoxyethylene ether sulfate or sodium dodecyl sulfate; The foam stabilizer is one of sodium stearate or silicone amide; Fly ash, slag powder, illite powder, and porous aggregate are added to a mixer for mixing, then crushed to prepare a composite powder with a particle size of 8-12 micrometers.

2. The core-foamed concrete insulation block according to claim 1, characterized in that, The core material comprises the following raw materials in parts by weight: 380 parts cement, 30 parts fly ash, 6 parts glass fiber, 0.5 parts foaming agent, 0.7 parts foam stabilizer, 1 part water-reducing agent, 25 parts slag powder, 5 parts polypropylene fiber, 20 parts illite powder, 8 parts porous aggregate, 0.7 parts sodium dodecylbenzenesulfonate, 0.6 parts cellulose-grafted methyl methacrylate, 30 parts hydrogen peroxide, and 50 parts water.

3. The core-foamed concrete insulation block according to claim 2, characterized in that, The water-reducing agent is a naphthalene sulfonate formaldehyde condensate.

4. A process for the production of core-foam concrete insulation blocks according to any one of claims 1 to 3, characterized in that, Includes the following steps: (1) Preparation of hollow bricks; (2) Preparation of cement foaming materials; a. Add fly ash, slag powder, illite powder, and porous aggregate to a mixer for mixing, then pulverize to prepare a composite powder; b. Mix cement and water in proportion at a speed of 40-50 rpm until homogeneous, then add composite powder, glass fiber and polypropylene fiber and mix until homogeneous to form the initial slurry; c. Prepare a foaming liquid by mixing foaming agent, foam stabilizer, water reducing agent, sodium dodecylbenzene sulfonate, cellulose-grafted methyl methacrylate and hydrogen peroxide in parts by weight. d. Add the foam liquid obtained in step c to the initial slurry obtained in step b, and stir evenly to obtain cement foaming material; (3) Fill the cavity of the hollow brick obtained in step (1) with cement foam material and cure it at room temperature until it is completely hardened.

5. The process for producing core-foam concrete insulation blocks according to claim 4, characterized in that, When the hollow bricks are filled with cement foaming material, the moisture content of the hollow bricks is 40%-60%.

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