Heat-preservation and heat-insulation gypsum-based self-leveling mortar and preparation method thereof

Abstract

The invention relates to the technical field of self-leveling mortar preparation, and particularly discloses heat-preservation and heat-insulation gypsum-based self-leveling mortar and a preparation method thereof.The preparation method comprises the steps that S1, fly ash, functional filler, silica powder, a water reducing agent, an expanding agent and a defoaming agent are premixed, and a premix is obtained after uniform mixing; and S2, uniformly mixing the cementing material and the premix to obtain the heat-preservation and heat-insulation gypsum-based self-leveling mortar. The prepared mortar is excellent in comprehensive performance, good in flowability, outstanding in mechanical property, high in compressive strength, excellent in impact resistance and breaking strength, capable of well absorbing and dispersing energy, good in bonding performance, capable of being firmly attached to the surface of a base layer, capable of avoiding the phenomena of hollowing, layering and the like in the using process, good in size stability, small in size change and capable of being widely applied to the field of building materials. The heat preservation and insulation effects are good, and heat transfer can be effectively prevented.

Description

Technical Field

[0001] The present application relates to the technical field of self-leveling mortar preparation, and more specifically, to a thermal insulation gypsum-based self-leveling mortar and a preparation method thereof. Background Art

[0002] With the increasing requirements of energy conservation and fire prevention for building exterior insulation systems in high-rise buildings, inorganic insulation materials will become the main direction of development of insulation materials in building exterior wall insulation systems due to their stable physical and chemical properties, good thermal insulation effects, and excellent fire resistance. Among them, gypsum-based self-leveling mortar has become a hot topic of research due to its convenient construction, good thermal insulation effect, and good sound insulation effect.

[0003] In the gypsum-based self-leveling mortar series, since the aggregate itself is a rigid particle, during climate change and frequent temperature rise and fall, the thermal insulation layer of the wall will produce certain stress. However, for rigid particles such as expanded perlite and vitrified microspheres, it is impossible to absorb this thermal expansion and contraction, wet expansion and dry shrinkage stress through deformation. In actual application, after the inorganic thermal insulation mortar is used to apply to the wall, the stress cannot be eliminated and strain is generated. When the strain accumulates to a certain extent, cracking occurs, further tearing the fireproof layer and the finishing layer. During seasonal changes, water seepage and freeze-thaw damage occur, and a "floatation" phenomenon forms on the molded surface, which then develops into large cracks and hollows, affecting the hardness, flatness and smoothness of the surface, and ultimately destroying the entire insulation system and reducing the service life. Based on the above statements, the present application provides a thermal insulation gypsum-based self-leveling mortar and a preparation method thereof. Summary of the invention

[0004] In order to solve the technical problems mentioned in the background technology, the present application provides a thermal insulation gypsum-based self-leveling mortar and a preparation method thereof.

[0005] In the first aspect, the present application provides a thermal insulation gypsum-based self-leveling mortar, which adopts the following technical solution: A thermal insulation gypsum-based self-leveling mortar comprises the following raw materials in parts by weight: 120-175 parts of a bonding material, 35-55 parts of fly ash, 35-58 parts of a functional filler, 12-18 parts of silicon micropowder, 1-3 parts of a water reducing agent, 4-6 parts of an expansion agent, 0.4-0.6 parts of a defoaming agent, and 120-150 parts of water.

[0006] Preferably, the bonding material consists of α-high-strength gypsum, silicate cement and fast-hardening sulphoaluminate cement.

[0007] Preferably, the total mass of the silicate cement and the rapid hardening sulphoaluminate cement is 20-32% of the α-high-strength gypsum.

[0008] Preferably, the mass ratio of the silicate cement to the rapid hardening sulphoaluminate cement is 10-12:1-3.

[0009] Preferably, the preparation of the functionalized filler comprises the following steps: Step A1, dispersing styrene-maleic anhydride copolymer and polystyrene in toluene, adding p-toluenesulfonic acid, and obtaining solution 1; dispersing acrylic acid nucleopolysaccharide in water, adding sodium carboxymethyl cellulose, and obtaining solution 2; Step A2, adding vitrified microspheres to solution 1, stirring at 40-60° C. and a stirring speed of 100-150 rpm for 20-24 h, filtering, and drying at 60-80° C. for 8-12 h to obtain modified vitrified microspheres; Step A3, dispersing the fiber material, AB2 type hyperbranched monomer, butyl acrylate and catalyst in toluene, under nitrogen protection, the reaction temperature is 80-120°C, stirring and reacting for 4-8 hours to obtain intermediate 1; adding modified glass microbeads, solution 2 and emulsifier to intermediate 1, stirring and reacting for 1-2 hours, cooling to room temperature, filtering, washing and drying to obtain functionalized filler.

[0010] Preferably, in step A1, solution 1 is composed of styrene-maleic anhydride copolymer, polystyrene, toluene and p-toluenesulfonic acid in a mass ratio of 100:30-45:300-400:0.5-1.

[0011] Preferably, the solution 2 is composed of acrylic acid ribopolysaccharide, deionized water and sodium carboxymethyl cellulose in a mass ratio of 8-10:100:1-2.

[0012] Preferably, in step A2, the mass ratio of the vitrified microspheres to the solution 1 is 2-5:10-12.

[0013] Preferably, in step A3, the mass ratio of the fiber material, the AB2 type hyperbranched monomer, butyl acrylate, the catalyst and toluene is 10-15: 3-5: 0.5-1: 0.005-0.01: 50-80.

[0014] Preferably, the fiber material in step A3 is one or more of glass fiber, carbon fiber, basalt fiber and slag wool.

[0015] Preferably, the AB2 type hyperbranched monomer is one of an AB2 type monomer containing a hydroxyl group and a carboxyl group, an AB2 type monomer containing a cyano group and a hydroxyl group, an AB2 type monomer containing an ester group and an amino group, and an AB2 type monomer containing anhydride and an amine group.

[0016] Preferably, in step A3, the ratio of intermediate 1, modified vitrified microspheres, solution 2 and emulsifier is 15-18: 3-6: 12-15: 0.2-0.4.

[0017] Preferably, the water reducer is a polycarboxylic acid-based high-performance water reducer and / or a naphthalene-based water reducer.

[0018] Preferably, the expansion agent is a UEA expansion agent and / or a magnesium oxide expansion agent.

[0019] Preferably, the defoamer is a polyether defoamer and / or a silicone defoamer.

[0020] In a second aspect, the present application also provides a method for preparing a thermal insulation gypsum-based self-leveling mortar, which adopts the following technical solution: Step S1, premixing fly ash, functional filler, silicon powder, water reducing agent, expansion agent and defoaming agent, and obtaining a premix after mixing evenly; Step S2: Evenly mix the binder material and the premix to obtain thermal insulation gypsum-based self-leveling mortar.

[0021] In summary, this application has the following beneficial effects: The present application utilizes a binder material composed of α-high-strength gypsum, silicate cement and fast-hardening sulphoaluminate cement, so that the gypsum-based self-leveling mortar has good strength performance both in the early and later stages, improves toughness, improves the internal structure of the mortar, and enables the mortar to resist deformation and cracking when subjected to stress. The combination of the three can adjust the setting time, and the hydrated calcium silicate generated by the hydration of silicate cement and the calcium aluminate generated by the hydration of fast-hardening sulphoaluminate cement can fill the pores inside the mortar, reduce the porosity, and increase the density, thereby enhancing the water resistance of the mortar, optimizing volume stability, compensating for shrinkage, reducing the shrinkage rate, and being less prone to problems such as softening and strength reduction.

[0022] The present application utilizes styrene-maleic anhydride copolymer and polystyrene to modify the vitrified microspheres. The modified vitrified microspheres have enhanced bonding strength with the gypsum matrix, can effectively transfer and disperse stress, improve mechanical properties such as compressive strength and flexural strength of the slurry, and can also reduce the water absorption of the vitrified microspheres, reduce the erosion of water on the gypsum matrix, improve the freeze-thaw resistance and weather resistance of the slurry, and extend the service life of the gypsum-based self-leveling floor. The modified vitrified microspheres still retain a large number of closed tiny pores inside, which can effectively prevent the transfer of heat. Polystyrene itself has good thermal insulation properties. After combining with vitrified microspheres, it effectively reduces the dissipation of indoor heat to the outside, reduces energy consumption, improves the thermal insulation performance of the building, and further enhances its thermal insulation effect.

[0023] This application uses AB2 type hyperbranched monomer and butyl acrylate to modify fiber materials, so that the fiber forms a highly branched three-dimensional structure, increases the entanglement between molecular chains, and gives the fiber higher strength and toughness. Butyl acrylate can adjust the flexibility of the molecular chain, so that the fiber has a certain rigidity and good softness, is not easy to break, and improves the mechanical properties of the fiber. Because the modified fiber has good mechanical properties and flexibility, it can play a role similar to "skeleton" in gypsum-based self-leveling slurry, resisting the shrinkage stress generated by the slurry during drying and use, effectively reducing the generation of cracks, improving the crack resistance of the slurry, and extending its service life. After the modified fiber is mixed with the modified glass microspheres, acrylic acid nucleopolysaccharide is added for composite modification to enhance the interfacial bonding of the functionalized filler and prevent it from falling off from the matrix. The functionalized filler can increase the fluidity of the self-leveling mortar matrix. After the acrylic acid nucleopolysaccharide is modified, a protective layer is formed around the functionalized filler particles to prevent the filler from settling in the mortar, ensure that the filler is evenly distributed in the mortar, increase the stability of the system, and reduce the stratification phenomenon caused by the density difference between different phases. Acrylic acid nucleopolysaccharide contains a large number of active functional groups such as carboxyl groups, which can react chemically with calcium ions or other metal ions in the matrix material to form chemical bonds. At the same time, it can also interact with the intermediates of the hyperbranched fiber material and the active groups on the surface of the modified glass microspheres, thereby building a strongly bonded interface layer between the filler and the matrix, improving the overall strength and durability of the self-leveling mortar. The fiber material in the functional filler is hyperbranched and the modified glass microspheres are bridged by acrylic acid nucleopolysaccharide to fill the gap between the two, making the contact between them closer and forming a mutually nested structure. This structure can effectively transfer stress when the self-leveling mortar is subjected to external forces, and improve the crack resistance and bearing capacity of the mortar. The network structure formed by the interaction of acrylic acid nucleopolysaccharide and other components has a certain degree of flexibility. This flexible network can absorb and disperse stress, prevent the occurrence of cracks when the self-leveling mortar is subjected to temperature changes, and make it more durable. DETAILED DESCRIPTION

[0024] The present application is further described in detail below with reference to the embodiments.

[0025] The α-high-strength gypsum (particle size: 2000 mesh) used in the examples of the present invention and the comparative examples was purchased from Hebei Mingzhe Mineral Products Co., Ltd.; silicate cement (model: gzk-005) was purchased from Guangzhou Qiangsheng Cement Grinding Co., Ltd.; rapid hardening sulphoaluminate cement (article number: R.SAC42.5) was purchased from Jiangxi Yinshan Super Materials Technology Co., Ltd.; fly ash (particle size: 325 mesh) was purchased from Lingshou County Zhan Teng Mineral Products Processing Plant; silicon powder (particle size: 325 mesh) was purchased from Hebei Leijiang New Materials Technology Co., Ltd.; styrene-maleic anhydride copolymer was purchased from Hubei Shuaiyan Ligao Biomedicine Co., Ltd.; polystyrene (brand name: GPPS-2 51) was purchased from Jinan Hongda Chemical Co., Ltd.; corn starch was purchased from Jinan Deqiao Chemical Technology Co., Ltd.; sodium carboxymethyl cellulose (article number: 03250906) was purchased from Jiangsu Jiujia Biotechnology Co., Ltd.; polycarboxylic acid-based high-performance water reducer (model: standard type) was purchased from Shandong Juxin New Materials Co., Ltd.; UEA expansion agent was purchased from Tianjin Daxiang Building Materials Co., Ltd.; silicone defoaming agent (model: th-5600) was purchased from Shandong Wanhua Tianhe New Materials Co., Ltd.; glass microspheres (mesh number: 60 mesh) were purchased from Hebei Hengguang Mineral Products Co., Ltd.; glass fiber (length: 6 mm) was purchased from Tai'an Songze Composite Materials Co., Ltd.

[0026] The preparation method of the acrylic acid nucleopolysaccharide used in the examples and comparative examples of the present invention is: Corn starch is dispersed in deionized water and stirred evenly to form a starch milk with a mass percentage concentration of 20%. The starch milk is heated and stirred at 60°C with a stirring speed of 100 rpm for 40 minutes to obtain pregelatinized starch. Acrylic acid is slowly added to a sodium hydroxide solution with a pH of 13 for neutralization reaction, and the neutralization degree is controlled to be 80% to obtain a sodium acrylate solution. The sodium acrylate solution and the pregelatinized starch are mixed in a ratio of 3:1, stirred at a stirring speed of 300 rpm for 30 minutes at room temperature, potassium persulfate and N,N'-methylenebisacrylamide are added, the temperature is raised to 80°C, stirred for 4 hours, cooled to room temperature, precipitated, filtered, washed, and dried to obtain acrylic acid nucleopolysaccharide, wherein the addition amounts of potassium persulfate and N,N'-methylenebisacrylamide are 0.5% and 0.1% of the mass of the sodium acrylate solution.

[0027] Embodiment 1-3 provides a thermal insulation gypsum-based self-leveling mortar and a preparation method thereof.

[0028] Example 1 A thermal insulation gypsum-based self-leveling mortar comprises the following raw materials in parts by weight: 120 parts of a binder, 35 parts of fly ash, 35 parts of a functional filler, 12 parts of silica powder, 1 part of a water reducer, 4 parts of an expansion agent, 0.4 parts of a defoamer, and 120 parts of water, wherein the binder consists of α-high-strength gypsum, silicate cement, and fast-hardening sulphoaluminate cement; the total mass of silicate cement and fast-hardening sulphoaluminate cement is 20% of the α-high-strength gypsum; the mass ratio of silicate cement to fast-hardening sulphoaluminate cement is 10:1; the water reducer is a polycarboxylic acid-based high-performance water reducer; the expansion agent is a UEA expansion agent; and the defoamer is an organosilicon defoamer.

[0029] The preparation of the functionalized filler comprises the following steps: Step A1, dispersing styrene-maleic anhydride copolymer and polystyrene in toluene, adding p-toluenesulfonic acid to obtain solution 1; dispersing acrylic acid nucleopolysaccharide in water, adding sodium carboxymethyl cellulose to obtain solution 2, wherein solution 1 is composed of styrene-maleic anhydride copolymer, polystyrene, toluene and p-toluenesulfonic acid in a mass ratio of 100:30:300:0.5; solution 2 is composed of acrylic acid nucleopolysaccharide, deionized water and sodium carboxymethyl cellulose in a mass ratio of 8:100:1; Step A2, adding vitrified microspheres to solution 1, stirring at 40° C. and a stirring speed of 100 rpm for 20 h, filtering, and drying at 60° C. for 8 h to obtain modified vitrified microspheres, wherein the mass ratio of vitrified microspheres to solution 1 is 1:5; Step A3, dispersing glass fiber, AB2 type hyperbranched monomer, butyl acrylate and p-toluenesulfonic acid in toluene, under nitrogen protection, the reaction temperature is 80°C, the stirring speed is 300 rpm, and the stirring reaction is carried out for 4 hours to obtain intermediate 1; adding modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate to intermediate 1, stirring and reacting for 1 hour, the stirring speed is 400 rpm, cooling to room temperature, filtering, washing and drying to obtain functionalized filler, wherein the mass ratio of fiber material, AB2 type hyperbranched monomer, butyl acrylate, p-toluenesulfonic acid and toluene is 10:3:0.5:0.005:50; the AB2 type hyperbranched monomer is an AB2 type monomer containing hydroxyl and carboxyl groups; the intermediate 1, modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate are 15:3:12:0.2.

[0030] A method for preparing a thermal insulation gypsum-based self-leveling mortar comprises the following steps: Step S1, premix fly ash, functional filler, silicon powder, water reducer, expansion agent and defoamer at a mixing speed of 100 rpm for 2 minutes, and obtain a premix after mixing evenly; Step S2: Evenly mix the binder material and the premix at a mixing speed of 100 rpm for 3 minutes to obtain a thermal insulation gypsum-based self-leveling mortar.

[0031] Example 2 A thermal insulation gypsum-based self-leveling mortar comprises the following raw materials in parts by weight: 150 parts of a binder, 45 parts of fly ash, 45 parts of a functional filler, 15 parts of silica powder, 2 parts of a water reducer, 5 parts of an expansion agent, 0.5 parts of a defoamer, and 135 parts of water, wherein the binder consists of α-high-strength gypsum, silicate cement, and fast-hardening sulphoaluminate cement; the total mass of silicate cement and fast-hardening sulphoaluminate cement is 26% of the α-high-strength gypsum; the mass ratio of silicate cement to fast-hardening sulphoaluminate cement is 11:2; the water reducer is a polycarboxylic acid-based high-performance water reducer; the expansion agent is a UEA expansion agent; and the defoamer is an organosilicon defoamer.

[0032] The preparation of the functionalized filler comprises the following steps: Step A1, dispersing styrene-maleic anhydride copolymer and polystyrene in toluene, adding p-toluenesulfonic acid to obtain solution 1; dispersing acrylic acid nucleopolysaccharide in water, adding sodium carboxymethyl cellulose to obtain solution 2, wherein solution 1 is composed of styrene-maleic anhydride copolymer, polystyrene, toluene and p-toluenesulfonic acid in a mass ratio of 100:35:350:0.8; solution 2 is composed of acrylic acid nucleopolysaccharide, deionized water and sodium carboxymethyl cellulose in a mass ratio of 9:100:1.5; Step A2, adding vitrified microspheres to solution 1, stirring at 50° C. and a stirring speed of 125 rpm for 22 h, filtering, and drying at 70° C. for 10 h to obtain modified vitrified microspheres, wherein the mass ratio of vitrified microspheres to solution 1 is 4:11; Step A3, dispersing glass fiber, AB2 type hyperbranched monomer, butyl acrylate and p-toluenesulfonic acid in toluene, under nitrogen protection, the reaction temperature is 100°C, the stirring speed is 400rpm, and the stirring reaction is carried out for 6 hours to obtain intermediate 1; adding modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate to intermediate 1, stirring and reacting for 1.5 hours, the stirring speed is 500rpm, cooling to room temperature, filtering, washing and drying to obtain functionalized filler, wherein the mass ratio of fiber material, AB2 type hyperbranched monomer, butyl acrylate, p-toluenesulfonic acid and toluene is 12:4:0.8:0.008:60; the AB2 type hyperbranched monomer is an AB2 type monomer containing hydroxyl and carboxyl groups; the intermediate 1, modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate are 17:4:13:0.3.

[0033] A method for preparing a thermal insulation gypsum-based self-leveling mortar comprises the following steps: Step S1, premix fly ash, functional filler, silicon powder, water reducer, expansion agent and defoamer at a mixing speed of 200 rpm for 2.5 min, and obtain a premix after mixing evenly; Step S2: Evenly mix the binder material and the premix at a mixing speed of 200 rpm for 4 minutes to obtain a thermal insulation gypsum-based self-leveling mortar.

[0034] Example 3 A thermal insulation gypsum-based self-leveling mortar comprises the following raw materials in parts by weight: 175 parts of a binder, 55 parts of fly ash, 58 parts of a functional filler, 18 parts of silica powder, 3 parts of a water reducer, 6 parts of an expansion agent, 0.6 parts of a defoamer, and 150 parts of water, wherein the binder consists of α-high-strength gypsum, silicate cement, and fast-hardening sulphoaluminate cement; the total mass of silicate cement and fast-hardening sulphoaluminate cement is 32% of the α-high-strength gypsum; the mass ratio of silicate cement to fast-hardening sulphoaluminate cement is 12:3; the water reducer is a polycarboxylic acid-based high-performance water reducer; the expansion agent is a UEA expansion agent; and the defoamer is an organosilicon defoamer.

[0035] The preparation of the functionalized filler comprises the following steps: Step A1, dispersing styrene-maleic anhydride copolymer and polystyrene in toluene, adding p-toluenesulfonic acid to obtain solution 1; dispersing acrylic acid nucleopolysaccharide in water, adding sodium carboxymethyl cellulose to obtain solution 2, wherein solution 1 is composed of styrene-maleic anhydride copolymer, polystyrene, toluene and p-toluenesulfonic acid in a mass ratio of 100:45:400:1; solution 2 is composed of acrylic acid nucleopolysaccharide, deionized water and sodium carboxymethyl cellulose in a mass ratio of 10:100:2; Step A2, adding vitrified microspheres to solution 1, stirring at 60° C. and a stirring speed of 150 rpm for 24 h, filtering, and drying at 80° C. for 12 h to obtain modified vitrified microspheres, wherein the mass ratio of vitrified microspheres to solution 1 is 5:12; Step A3, dispersing glass fiber, AB2 type hyperbranched monomer, butyl acrylate and p-toluenesulfonic acid in toluene, under nitrogen protection, the reaction temperature is 120°C, the stirring speed is 500 rpm, and the stirring reaction is carried out for 8 hours to obtain intermediate 1; adding modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate to intermediate 1, stirring and reacting for 2 hours, the stirring speed is 600 rpm, cooling to room temperature, filtering, washing and drying to obtain functionalized filler, wherein the mass ratio of fiber material, AB2 type hyperbranched monomer, butyl acrylate, p-toluenesulfonic acid and toluene is 15:5:1:0.01:80; the AB2 type hyperbranched monomer is an AB2 type monomer containing hydroxyl and carboxyl groups; the intermediate 1, modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate are 18:6:15:0.4.

[0036] A method for preparing a thermal insulation gypsum-based self-leveling mortar comprises the following steps: Step S1, premix fly ash, functional filler, silicon powder, water reducer, expansion agent and defoamer at a mixing speed of 300 rpm for 3 minutes, and obtain a premix after mixing evenly; Step S2: Evenly mix the binder material and the premix at a mixing speed of 300 rpm for 5 minutes to obtain a thermal insulation gypsum-based self-leveling mortar.

[0037] Comparative Example 1 A thermal insulation gypsum-based self-leveling mortar comprises the following raw materials in parts by weight: 120 parts of a binder, 35 parts of fly ash, 35 parts of a functional filler, 12 parts of silica powder, 1 part of a water reducer, 4 parts of an expansion agent, 0.4 parts of a defoamer, and 120 parts of water, wherein the binder consists of α-high-strength gypsum and silicate cement; the silicate cement accounts for 20% of the α-high-strength gypsum; the water reducer is a polycarboxylic acid-based high-performance water reducer; the expansion agent is a UEA expansion agent; and the defoamer is an organosilicon defoamer.

[0038] The preparation of the functionalized filler comprises the following steps: Step A1, dispersing styrene-maleic anhydride copolymer and polystyrene in toluene, adding p-toluenesulfonic acid to obtain solution 1; dispersing acrylic acid nucleopolysaccharide in water, adding sodium carboxymethyl cellulose to obtain solution 2, wherein solution 1 is composed of styrene-maleic anhydride copolymer, polystyrene, toluene and p-toluenesulfonic acid in a mass ratio of 100:30:300:0.5; solution 2 is composed of acrylic acid nucleopolysaccharide, deionized water and sodium carboxymethyl cellulose in a mass ratio of 8:100:1; Step A2, adding vitrified microspheres to solution 1, stirring at 40° C. and a stirring speed of 100 rpm for 20 h, filtering, and drying at 60° C. for 8 h to obtain modified vitrified microspheres, wherein the mass ratio of vitrified microspheres to solution 1 is 1:5; Step A3, dispersing glass fiber, AB2 type hyperbranched monomer, butyl acrylate and p-toluenesulfonic acid in toluene, under nitrogen protection, the reaction temperature is 80°C, the stirring speed is 300 rpm, and the stirring reaction is carried out for 4 hours to obtain intermediate 1; adding modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate to intermediate 1, stirring and reacting for 1 hour, the stirring speed is 400 rpm, cooling to room temperature, filtering, washing and drying to obtain functionalized filler, wherein the mass ratio of fiber material, AB2 type hyperbranched monomer, butyl acrylate, p-toluenesulfonic acid and toluene is 10:3:0.5:0.005:50; the AB2 type hyperbranched monomer is an AB2 type monomer containing hydroxyl and carboxyl groups; the intermediate 1, modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate are 15:3:12:0.2.

[0039] A method for preparing a thermal insulation gypsum-based self-leveling mortar comprises the following steps: Step S1, premix fly ash, functional filler, silicon powder, water reducer, expansion agent and defoamer at a mixing speed of 100 rpm for 2 minutes, and obtain a premix after mixing evenly; Step S2: Evenly mix the binder material and the premix at a mixing speed of 100 rpm for 3 minutes to obtain a thermal insulation gypsum-based self-leveling mortar.

[0040] Comparative Example 2 A thermal insulation gypsum-based self-leveling mortar comprises the following raw materials in parts by weight: 120 parts of a binder, 35 parts of fly ash, 35 parts of a functional filler, 12 parts of silica powder, 1 part of a water reducer, 4 parts of an expansion agent, 0.4 parts of a defoamer, and 120 parts of water, wherein the binder consists of α-high-strength gypsum, silicate cement, and fast-hardening sulphoaluminate cement; the total mass of silicate cement and fast-hardening sulphoaluminate cement is 40% of the α-high-strength gypsum; the mass ratio of silicate cement to fast-hardening sulphoaluminate cement is 10:1; the water reducer is a polycarboxylic acid-based high-performance water reducer; the expansion agent is a UEA expansion agent; and the defoamer is an organosilicon defoamer. The preparation of the functionalized filler comprises the following steps: Step A1, dispersing styrene-maleic anhydride copolymer and polystyrene in toluene, adding p-toluenesulfonic acid to obtain solution 1; dispersing acrylic acid nucleopolysaccharide in water, adding sodium carboxymethyl cellulose to obtain solution 2, wherein solution 1 is composed of styrene-maleic anhydride copolymer, polystyrene, toluene and p-toluenesulfonic acid in a mass ratio of 100:30:300:0.5; solution 2 is composed of acrylic acid nucleopolysaccharide, deionized water and sodium carboxymethyl cellulose in a mass ratio of 8:100:1; Step A2, adding vitrified microspheres to solution 1, stirring at 40° C. and a stirring speed of 100 rpm for 20 h, filtering, and drying at 60° C. for 8 h to obtain modified vitrified microspheres, wherein the mass ratio of vitrified microspheres to solution 1 is 1:5; Step A3, dispersing glass fiber, AB2 type hyperbranched monomer, butyl acrylate and p-toluenesulfonic acid in toluene, under nitrogen protection, the reaction temperature is 80°C, the stirring speed is 300 rpm, and the stirring reaction is carried out for 4 hours to obtain intermediate 1; adding modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate to intermediate 1, stirring and reacting for 1 hour, the stirring speed is 400 rpm, cooling to room temperature, filtering, washing and drying to obtain functionalized filler, wherein the mass ratio of fiber material, AB2 type hyperbranched monomer, butyl acrylate, p-toluenesulfonic acid and toluene is 10:3:0.5:0.005:50; the AB2 type hyperbranched monomer is an AB2 type monomer containing hydroxyl and carboxyl groups; the intermediate 1, modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate are 15:3:12:0.2.

[0041] A method for preparing a thermal insulation gypsum-based self-leveling mortar comprises the following steps: Step S1, premix fly ash, functional filler, silicon powder, water reducer, expansion agent and defoamer at a mixing speed of 100 rpm for 2 minutes, and obtain a premix after mixing evenly; Step S2: Evenly mix the binder material and the premix at a mixing speed of 100 rpm for 3 minutes to obtain a thermal insulation gypsum-based self-leveling mortar.

[0042] Comparative Example 3 A thermal insulation gypsum-based self-leveling mortar comprises the following raw materials in parts by weight: 120 parts of a binder, 35 parts of fly ash, 35 parts of a functional filler, 12 parts of silica powder, 1 part of a water reducer, 4 parts of an expansion agent, 0.4 parts of a defoamer, and 120 parts of water, wherein the binder consists of α-high-strength gypsum, silicate cement, and fast-hardening sulphoaluminate cement; the total mass of silicate cement and fast-hardening sulphoaluminate cement is 20% of the α-high-strength gypsum; the mass ratio of silicate cement to fast-hardening sulphoaluminate cement is 10:1; the water reducer is a polycarboxylic acid-based high-performance water reducer; the expansion agent is a UEA expansion agent; and the defoamer is an organosilicon defoamer.

[0043] The preparation of the functionalized filler comprises the following steps: Step A1, dispersing polystyrene in toluene, adding p-toluenesulfonic acid to obtain solution 1; dispersing acrylic acid nucleopolysaccharide in water, adding sodium carboxymethyl cellulose to obtain solution 2, wherein solution 1 is composed of polystyrene, toluene and p-toluenesulfonic acid in a mass ratio of 130:300:0.5; solution 2 is composed of acrylic acid nucleopolysaccharide, deionized water and sodium carboxymethyl cellulose in a mass ratio of 8:100:1; Step A2, adding vitrified microspheres to solution 1, stirring at 40° C. and a stirring speed of 100 rpm for 20 h, filtering, and drying at 60° C. for 8 h to obtain modified vitrified microspheres, wherein the mass ratio of vitrified microspheres to solution 1 is 1:5; Step A3, dispersing glass fiber, AB2 type hyperbranched monomer, butyl acrylate and p-toluenesulfonic acid in toluene, under nitrogen protection, the reaction temperature is 80°C, the stirring speed is 300 rpm, and the stirring reaction is carried out for 4 hours to obtain intermediate 1; adding modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate to intermediate 1, stirring and reacting for 1 hour, the stirring speed is 400 rpm, cooling to room temperature, filtering, washing and drying to obtain functionalized filler, wherein the mass ratio of fiber material, AB2 type hyperbranched monomer, butyl acrylate, p-toluenesulfonic acid and toluene is 10:3:0.5:0.005:50; the AB2 type hyperbranched monomer is an AB2 type monomer containing hydroxyl and carboxyl groups; the intermediate 1, modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate are 15:3:12:0.2.

[0044] A method for preparing a thermal insulation gypsum-based self-leveling mortar comprises the following steps: Step S1, premix fly ash, functional filler, silicon powder, water reducer, expansion agent and defoamer at a mixing speed of 100 rpm for 2 minutes, and obtain a premix after mixing evenly; Step S2: Evenly mix the binder material and the premix at a mixing speed of 100 rpm for 3 minutes to obtain a thermal insulation gypsum-based self-leveling mortar.

[0045] Comparative Example 4 A thermal insulation gypsum-based self-leveling mortar comprises the following raw materials in parts by weight: 120 parts of a binder, 35 parts of fly ash, 35 parts of a functional filler, 12 parts of silica powder, 1 part of a water reducer, 4 parts of an expansion agent, 0.4 parts of a defoamer, and 120 parts of water, wherein the binder consists of α-high-strength gypsum, silicate cement, and fast-hardening sulphoaluminate cement; the total mass of silicate cement and fast-hardening sulphoaluminate cement is 20% of the α-high-strength gypsum; the mass ratio of silicate cement to fast-hardening sulphoaluminate cement is 10:1; the water reducer is a polycarboxylic acid-based high-performance water reducer; the expansion agent is a UEA expansion agent; and the defoamer is an organosilicon defoamer.

[0046] The preparation of the functionalized filler comprises the following steps: Step A1, dispersing styrene-maleic anhydride copolymer in toluene, adding p-toluenesulfonic acid to obtain solution 1; dispersing acrylic acid nucleopolysaccharide in water, adding sodium carboxymethyl cellulose to obtain solution 2, wherein solution 1 is composed of styrene-maleic anhydride copolymer, toluene and p-toluenesulfonic acid in a mass ratio of 130:300:0.5; solution 2 is composed of acrylic acid nucleopolysaccharide, deionized water and sodium carboxymethyl cellulose in a mass ratio of 8:100:1; Step A2, adding vitrified microspheres to solution 1, stirring at 40° C. and a stirring speed of 100 rpm for 20 h, filtering, and drying at 60° C. for 8 h to obtain modified vitrified microspheres, wherein the mass ratio of vitrified microspheres to solution 1 is 1:5; Step A3, dispersing glass fiber, AB2 type hyperbranched monomer, butyl acrylate and p-toluenesulfonic acid in toluene, under nitrogen protection, the reaction temperature is 80°C, the stirring speed is 300 rpm, and the stirring reaction is carried out for 4 hours to obtain intermediate 1; adding modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate to intermediate 1, stirring and reacting for 1 hour, the stirring speed is 400 rpm, cooling to room temperature, filtering, washing and drying to obtain functionalized filler, wherein the mass ratio of fiber material, AB2 type hyperbranched monomer, butyl acrylate, p-toluenesulfonic acid and toluene is 10:3:0.5:0.005:50; the AB2 type hyperbranched monomer is an AB2 type monomer containing hydroxyl and carboxyl groups; the intermediate 1, modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate are 15:3:12:0.2.

[0047] A method for preparing a thermal insulation gypsum-based self-leveling mortar comprises the following steps: Step S1, premix fly ash, functional filler, silicon powder, water reducer, expansion agent and defoamer at a mixing speed of 100 rpm for 2 minutes, and obtain a premix after mixing evenly; Step S2: Evenly mix the binder material and the premix at a mixing speed of 100 rpm for 3 minutes to obtain a thermal insulation gypsum-based self-leveling mortar.

[0048] Comparative Example 5 A thermal insulation gypsum-based self-leveling mortar comprises the following raw materials in parts by weight: 120 parts of a binder, 35 parts of fly ash, 35 parts of a functional filler, 12 parts of silica powder, 1 part of a water reducer, 4 parts of an expansion agent, 0.4 parts of a defoamer, and 120 parts of water, wherein the binder consists of α-high-strength gypsum, silicate cement, and fast-hardening sulphoaluminate cement; the total mass of silicate cement and fast-hardening sulphoaluminate cement is 20% of the α-high-strength gypsum; the mass ratio of silicate cement to fast-hardening sulphoaluminate cement is 10:1; the water reducer is a polycarboxylic acid-based high-performance water reducer; the expansion agent is a UEA expansion agent; and the defoamer is an organosilicon defoamer.

[0049] The preparation of the functionalized filler comprises the following steps: Step A1, dispersing styrene-maleic anhydride copolymer and polystyrene in toluene, adding p-toluenesulfonic acid to obtain solution 1; dispersing acrylic acid nucleopolysaccharide in water, adding sodium carboxymethyl cellulose to obtain solution 2, wherein solution 1 is composed of styrene-maleic anhydride copolymer, polystyrene, toluene and p-toluenesulfonic acid in a mass ratio of 100:30:300:0.5; solution 2 is composed of acrylic acid nucleopolysaccharide, deionized water and sodium carboxymethyl cellulose in a mass ratio of 8:100:1; Step A2, adding vitrified microspheres to solution 2, stirring at 40°C with a stirring speed of 100 rpm for 20 hours, filtering, and drying at 60°C for 8 hours to obtain modified vitrified microspheres, wherein the mass ratio of vitrified microspheres to solution 2 is 1:5; Step A3, dispersing glass fiber, AB2 type hyperbranched monomer, butyl acrylate and p-toluenesulfonic acid in toluene, under nitrogen protection, the reaction temperature is 80°C, the stirring speed is 300 rpm, and the stirring reaction is carried out for 4 hours to obtain intermediate 1; adding modified glass microspheres, solution 1 and sodium dodecylbenzene sulfonate to intermediate 1, stirring and reacting for 1 hour, the stirring speed is 400 rpm, cooling to room temperature, filtering, washing and drying to obtain functionalized filler, wherein the mass ratio of fiber material, AB2 type hyperbranched monomer, butyl acrylate, p-toluenesulfonic acid and toluene is 10:3:0.5:0.005:50; the AB2 type hyperbranched monomer is an AB2 type monomer containing hydroxyl and carboxyl groups; the intermediate 1, modified glass microspheres, solution 1 and sodium dodecylbenzene sulfonate are 15:3:12:0.2.

[0050] A method for preparing a thermal insulation gypsum-based self-leveling mortar comprises the following steps: Step S1, premix fly ash, functional filler, silicon powder, water reducer, expansion agent and defoamer at a mixing speed of 100 rpm for 2 minutes, and obtain a premix after mixing evenly; Step S2: Evenly mix the binder material and the premix at a mixing speed of 100 rpm for 3 minutes to obtain a thermal insulation gypsum-based self-leveling mortar.

[0051] Comparative Example 6 A thermal insulation gypsum-based self-leveling mortar comprises the following raw materials in parts by weight: 120 parts of a binder, 35 parts of fly ash, 35 parts of a functional filler, 12 parts of silica powder, 1 part of a water reducer, 4 parts of an expansion agent, 0.4 parts of a defoamer, and 120 parts of water, wherein the binder consists of α-high-strength gypsum, silicate cement, and fast-hardening sulphoaluminate cement; the total mass of silicate cement and fast-hardening sulphoaluminate cement is 20% of the α-high-strength gypsum; the mass ratio of silicate cement to fast-hardening sulphoaluminate cement is 10:1; the water reducer is a polycarboxylic acid-based high-performance water reducer; the expansion agent is a UEA expansion agent; and the defoamer is an organosilicon defoamer.

[0052] The preparation of the functionalized filler comprises the following steps: Step A1, dispersing styrene-maleic anhydride copolymer and polystyrene in toluene, adding p-toluenesulfonic acid to obtain solution 1; dispersing acrylic acid nucleopolysaccharide in water, adding sodium carboxymethyl cellulose to obtain solution 2, wherein solution 1 is composed of styrene-maleic anhydride copolymer, polystyrene, toluene and p-toluenesulfonic acid in a mass ratio of 100:30:300:0.5; solution 2 is composed of acrylic acid nucleopolysaccharide, deionized water and sodium carboxymethyl cellulose in a mass ratio of 8:100:1; Step A2, adding vitrified microspheres to solution 1, stirring at 40° C. and a stirring speed of 100 rpm for 20 h, filtering, and drying at 60° C. for 8 h to obtain modified vitrified microspheres, wherein the mass ratio of vitrified microspheres to solution 1 is 1:5; Step A3, dispersing glass fiber, AB2 type hyperbranched monomer and p-toluenesulfonic acid in toluene, under nitrogen protection, the reaction temperature is 80°C, the stirring speed is 300 rpm, and the stirring reaction is carried out for 4 hours to obtain intermediate 1; adding modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate to intermediate 1, stirring and reacting for 1 hour, the stirring speed is 400 rpm, cooling to room temperature, filtering, washing and drying to obtain functionalized filler, wherein the mass ratio of fiber material, AB2 type hyperbranched monomer, p-toluenesulfonic acid and toluene is 10:3:0.005:50; the AB2 type hyperbranched monomer is an AB2 type monomer containing hydroxyl and carboxyl groups; intermediate 1, modified glass microspheres, solution 2 and sodium dodecylbenzene sulfonate are 15:3:12:0.2.

[0053] A method for preparing a thermal insulation gypsum-based self-leveling mortar comprises the following steps: Step S1, premix fly ash, functional filler, silicon powder, water reducer, expansion agent and defoamer at a mixing speed of 100 rpm for 2 minutes, and obtain a premix after mixing evenly; Step S2: Evenly mix the binder material and the premix at a mixing speed of 100 rpm for 3 minutes to obtain a thermal insulation gypsum-based self-leveling mortar.

[0054] Performance Testing The comprehensive properties of the thermal insulation self-leveling mortars prepared in Examples 1-3 and Comparative Examples 1-6 of the present application are as follows: Fluidity, compressive strength, impact resistance, flexural strength, drying tensile bond strength and dimensional change rate: measured in accordance with the industry standard JC / T 1023-2021 "Gypsum-based self-leveling mortar"; Thermal insulation performance: tested in accordance with the industry standard JG / T 266-2011 "Foamed concrete"; The test results are shown in Table 1 below.

[0055] Table 1 Performance parameters of gypsum-based self-leveling mortars prepared in Examples 1-3 and Comparative Examples 1-6

[0056] It can be seen from the data shown in Table 1 above that the mortar prepared in the present application has excellent comprehensive performance, excellent flowability, outstanding mechanical properties, high compressive strength and excellent impact resistance, can absorb and disperse energy well, has good flexural strength and good bonding properties, can firmly adhere to the surface of the base layer, and avoids hollowing, delamination and the like during use. It has good dimensional stability, small volume change, good thermal insulation effect, and can effectively prevent the transfer of heat.

[0057] This specific embodiment is merely an explanation of the present application and is not a limitation of the present application. After reading this specification, those skilled in the art may make modifications to the present embodiment without any creative contribution as needed, but such modifications are protected by the patent law as long as they are within the scope of the claims of the present application.

Claims

1. A thermal insulation gypsum-based self-leveling mortar, characterized in that: The invention comprises the following raw materials in parts by weight: 120-175 parts of cementitious material, 35-55 parts of fly ash, 35-58 parts of functional filler, 12-18 parts of silicon micropowder, 1-3 parts of water reducing agent, 4-6 parts of expansion agent, 0.4-0.6 parts of defoaming agent and 120-150 parts of water.

2. The thermal insulation gypsum-based self-leveling mortar according to claim 1, characterized in that: The bonding material consists of α-high-strength gypsum, silicate cement and fast-hardening sulphoaluminate cement; the total mass of the silicate cement and the fast-hardening sulphoaluminate cement is 20-32% of the α-high-strength gypsum; the mass ratio of the silicate cement to the fast-hardening sulphoaluminate cement is 10-12:1-3.

3. The thermal insulation gypsum-based self-leveling mortar according to claim 1, characterized in that: The preparation of the functionalized filler comprises the following steps: Step A1, dispersing styrene-maleic anhydride copolymer and polystyrene in toluene, adding p-toluenesulfonic acid, and obtaining solution 1; dispersing acrylic acid nucleopolysaccharide in water, adding sodium carboxymethyl cellulose, and obtaining solution 2; Step A2, adding vitrified microspheres to solution 1, stirring at 40-60° C. and a stirring speed of 100-150 rpm for 20-24 h, filtering, and drying at 60-80° C. for 8-12 h to obtain modified vitrified microspheres; Step A3, dispersing the fiber material, AB2 type hyperbranched monomer, butyl acrylate and catalyst in toluene, under nitrogen protection, the reaction temperature is 80-120°C, stirring and reacting for 4-8 hours to obtain intermediate 1; adding modified glass microbeads, solution 2 and emulsifier to intermediate 1, stirring and reacting for 1-2 hours, cooling to room temperature, filtering, washing and drying to obtain functionalized filler.

4. The thermal insulation gypsum-based self-leveling mortar according to claim 3, characterized in that: In step A1, solution 1 is composed of styrene-maleic anhydride copolymer, polystyrene, toluene and p-toluenesulfonic acid in a mass ratio of 100:30-45:300-400:0.5-1; solution 2 is composed of acrylic acid nucleopolysaccharide, deionized water and sodium carboxymethyl cellulose in a mass ratio of 8-10:100:1-2.

5. The thermal insulation gypsum-based self-leveling mortar according to claim 3, characterized in that: In the step A2, the mass ratio of the vitrified microspheres to the solution 1 is 2-5:10-12.

6. The thermal insulation gypsum-based self-leveling mortar according to claim 3, characterized in that: In the step A3, the mass ratio of the fiber material, the AB2 type hyperbranched monomer, butyl acrylate, the catalyst and toluene is 10-15: 3-5: 0.5-1: 0.005-0.01: 50-80.

7. The thermal insulation gypsum-based self-leveling mortar according to claim 3, characterized in that: The fiber material in step A3 is one or more of glass fiber, carbon fiber, basalt fiber and slag wool; the AB2 type hyperbranched monomer is one of an AB2 type monomer containing hydroxyl and carboxyl groups, an AB2 type monomer containing cyano and hydroxyl groups, an AB2 type monomer containing ester groups and amino groups, and an AB2 type monomer containing acid anhydride and amine groups.

8. The thermal insulation gypsum-based self-leveling mortar according to claim 3, characterized in that: In the step A3, the intermediate 1, the modified glass microspheres, the solution 2 and the emulsifier are 15-18: 3-6: 12-15: 0.2-0.

4.

9. The thermal insulation gypsum-based self-leveling mortar according to claim 1, characterized in that: The water reducer is a polycarboxylic acid high-performance water reducer and / or a naphthalene water reducer; the expansion agent is a UEA expansion agent and / or a magnesium oxide expansion agent; and the defoamer is a polyether defoamer and / or an organosilicon defoamer.

10. A method for preparing the thermal insulation gypsum-based self-leveling mortar according to any one of claims 1 to 9, characterized in that: The following steps are involved: Step S1, premixing fly ash, functional filler, silicon powder, water reducing agent, expansion agent and defoaming agent, and obtaining a premix after mixing evenly; Step S2: Evenly mix the binder material and the premix to obtain thermal insulation gypsum-based self-leveling mortar.

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