Gypsum-based composite sound insulation mortar as well as preparation method and application thereof

Abstract

The invention discloses gypsum-based composite sound insulation mortar as well as a preparation method and application thereof. The gypsum-based composite sound insulation mortar comprises the following components in parts by weight: 40-60 parts of desulfurized gypsum, 10-20 parts of calcite, 5-10 parts of ash calcium, 2-5 parts of redispersible latex powder, 3-8 parts of polypropylene fibers, 15-25 parts of glass beads, 0.2-0.8 part of a water-retaining agent, 0.1-0.5 part of a retarder and 0.1-0.5 part of a water reducing agent. The gypsum-based composite sound insulation mortar provided by the invention has excellent sound absorption and insulation performance, good construction performance, outstanding fireproof performance and durability, is suitable for building wall sound insulation, indoor partition sound insulation and ground sound insulation projects, and has a wide market application prospect.

Description

Technical Field

[0001] The present invention relates to the technical field of building materials, and particularly relates to a gypsum-based composite sound insulation mortar, a preparation method thereof, and an application thereof. Background Art

[0002] With the rapid development of the urbanization process, the building density is increasing day by day, and the noise generated by transportation, industry, and life seriously interferes with people's living and working environments. The sound insulation performance of traditional ordinary cement mortar is limited and it is difficult to meet the strict requirements of modern buildings for the acoustic environment. Although organic sound insulation materials have good sound insulation effects, they have problems such as poor fire resistance and insufficient durability. Therefore, it is urgent to develop a building sound insulation material with good sound absorption and insulation performance, environmental protection, fire resistance, and excellent durability. Summary of the Invention

[0003] The purpose of the present invention is to provide a gypsum-based composite sound insulation mortar, a preparation method thereof, and an application thereof, so as to solve the problem that the sound insulation effect, fire resistance, and durability in the prior art cannot reach ideal effects at the same time.

[0004] To achieve the above purpose, the present invention provides the following technical solutions: The gypsum-based composite sound insulation mortar provided by the present invention includes the following components in parts by weight: 40-60 parts of desulfurized gypsum, 10-20 parts of calcite, 5-10 parts of hydrated lime, 2-5 parts of redispersible latex powder, 3-8 parts of polypropylene fiber, 15-25 parts of vitrified microspheres, 0.2-0.8 part of water retaining agent, 0.1-0.5 part of retarder, and 0.1-0.5 part of water reducing agent.

[0005] Desulfurized gypsum, as the main cementitious material, has the advantages of fast setting and hardening, good fire resistance, environmental protection, etc., and provides basic strength and bonding performance.

[0006] Calcite, as a filler, improves the density and durability of the mortar, and at the same time improves the construction performance.

[0007] Hydrated lime enhances the bonding property and crack resistance of the mortar and improves the overall strength.

[0008] Further, the redispersible latex powder is one or more of ethylene / vinyl acetate copolymer, vinyl acetate / vinyl versatate copolymer, acrylic copolymer, styrene-acrylate, butadiene-styrene latex, ethylene-vinyl chloride-vinyl laurate, ethylene-vinyl acetate-vinyl ester.

[0009] The redispersible latex powder improves the bonding property and flexibility of the mortar, and enhances the integrity and durability.

[0010] Polypropylene fiber, as a fibrous sound insulation additive, forms a three-dimensional network structure, increasing the sound propagation path and the number of reflections, improving the sound absorption and insulation effect, and enhancing the crack resistance performance.

[0011] Vitrified microspheres, as lightweight aggregates, have an internal porous structure that effectively blocks sound propagation, reduces the density of the mortar, and lightens the building load.

[0012] Furthermore, the water retention agent is hydroxypropyl methylcellulose or methylcellulose, which retains the moisture in the mortar, delays the setting time of gypsum, and ensures the workability and spreading performance during construction.

[0013] Furthermore, the retarder is sodium gluconate, and the water reducer is a polycarboxylate-based high-performance water reducer.

[0014] Retarders can effectively postpone the hydration reaction of cement, extend the setting time of concrete, reduce the hydration rate and hydration heat, and mainly include two categories: inorganic retarders and organic retarders: Inorganic retarders include: ‌Phosphates, metaphosphates‌: Such as sodium pyrophosphate (Na2P2O7). Among phosphate-based retarders, sodium pyrophosphate has the strongest retardation effect at the same dosage.

[0015] ‌Borax (Na2B4O7·10H2O)‌: A white powdery crystalline substance, highly hygroscopic, easily soluble in water and glycerol, and its aqueous solution is weakly alkaline.

[0016] ‌Sodium fluorosilicate (Na2SiF6)‌: A white crystalline substance, slightly soluble in water, insoluble in ethanol, and corrosive.

[0017] ‌Other inorganic retarders‌: Such as zinc chloride, zinc carbonate, and sulfates of zinc, iron, and copper. Although they have a certain retardation effect, they are not commonly used due to unstable effects.

[0018] Organic retarders include the following: ‌Hydroxycarboxylic acids, aminocarboxylic acids and their salts‌: Such as citric acid, tartaric acid, gluconic acid, etc.

[0019] ‌Polyhydric alcohols and their derivatives‌: Such as ethylene glycol, propylene glycol, glycerol, etc. Their retardation effect is stronger than that of monohydric alcohols. At the same dosage, the setting time is extended by 2 - 8 hours.

[0020] ‌Sugars‌: Such as glucose, sucrose and their derivatives, and molasses and their derivatives, which are widely used.

[0021] The polycarboxylate-based high-performance water reducer reduces the water consumption, improves the strength and density of the mortar, and indirectly enhances the sound insulation effect.

[0022] The present invention adopts sodium gluconate as a retarder to adjust the setting time of mortar and improve the construction performance.

[0023] The present invention also provides a method for preparing a gypsum-based composite sound insulation mortar, comprising the following steps: S1. Add desulfurized gypsum, calcite, lime lime and vitrified microspheres into a dry powder mixer and stir for 5-10 minutes to mix them evenly. S2. Add polypropylene fiber and continue stirring for 3-5 minutes; S3. Add redispersible latex powder, water retaining agent, retarder and water reducing agent, stir for 8-15 minutes to obtain a uniform gypsum-based composite sound insulation mortar.

[0024] The sound insulation performance is significantly improved through the synergistic effect of specific proportions of desulfurized gypsum, calcite, lime calcium, polypropylene fiber and glass beads.

[0025] Preparation process: A step-by-step mixing process is used to ensure that all ingredients are evenly dispersed to maximize their effectiveness.

[0026] Comprehensive performance: It has excellent sound absorption, sound insulation and fire prevention, filling the gap in existing technology.

[0027] Beneficial effects of setting the proportion of each component 1. Desulfurized gypsum (40-60 parts): This ratio range ensures the basic performance of the mortar. As the main cementitious material, desulfurized gypsum cannot provide sufficient strength and adhesion when its content is too low, resulting in the mortar being unable to effectively bond to the base material during use, and being prone to falling off. In addition, the overall strength is insufficient and cannot withstand a certain load. Excessive content may increase the shrinkage of the mortar, and cracks may easily form during the hardening process, affecting the durability and aesthetics of the mortar. For example, when the desulfurized gypsum is 50 parts in Example 1, the compressive strength reaches 5MPa, the bonding strength is 0.6MPa, and the fire resistance grade reaches Class A. Various properties achieve a good balance, indicating that this ratio can give full play to the advantages of desulfurized gypsum such as fast coagulation and hardening, good fire resistance, and environmental protection, while ensuring that the mortar has good basic properties.

[0028] 2. Calcite (10-20 parts): In this ratio range, calcite can effectively play its role as a filler. When the calcite content is less than 10 parts, the effect of improving the density and durability of the mortar is not obvious, and the pores inside the mortar cannot be fully filled, resulting in insufficient density of the mortar, which is easily eroded by the external environment and reduced durability. When the content is higher than 20 parts, the weight of the mortar will increase too much, which not only increases the difficulty of transportation and construction, but may also affect other properties of the mortar, such as reducing sound absorption and sound insulation performance, because too much calcite will fill the pores of materials such as vitrified microspheres, reducing the sound barrier and absorption space.

[0029] 3. Hydrated lime (5 - 10 parts): This proportion range is crucial for the bonding and crack resistance of the mortar. If the content of hydrated lime is too low, the effects of enhancing the bonding and crack resistance are not significant, and it cannot meet the requirements of actual projects for crack resistance and bonding strength. Problems such as cracking and poor bonding are likely to occur during the use of the mortar. When the content is too high, the alkalinity of the mortar will be too strong, which may cause adverse reactions with other additives, affect the performance of other components, and lead to a decline in the comprehensive performance of the mortar. For example, it may affect the flexibility and bonding effect of the redispersible latex powder, making the mortar brittle and more prone to cracking. In the examples, the bonding strength and compressive strength can be maintained within a reasonable range under different proportions of hydrated lime, proving the rationality of this proportion.

[0030] 4. Redispersible latex powder (2 - 5 parts): Within the range of 2 - 5 parts, the latex powder can effectively improve the performance of the mortar. If the content of the latex powder is less than 2 parts, the improvement effects on the bonding and flexibility of the mortar are limited. The mortar may have poor bonding when bonding to the base material, and it is prone to cracking due to lack of flexibility when subjected to external forces or temperature changes. When the content of the latex powder is higher than 5 parts, although the bonding and flexibility will be further improved, the production cost will increase significantly. At the same time, it may slow down the drying speed of the mortar and the strength growth is slow, affecting the construction progress and project quality. The data in the examples show that the mortar has good bonding performance and stable overall performance at this proportion, indicating that this proportion is more appropriate.

[0031] 5. Polypropylene fiber (3 - 8 parts): This proportion can not only ensure that the polypropylene fiber plays a role in enhancing sound absorption, sound insulation, and crack resistance, but also will not have a negative impact on other properties of the mortar. When the content of polypropylene fiber is less than 3 parts, the formed three-dimensional network structure is not perfect enough, which cannot sufficiently increase the sound propagation path and the number of reflections, and the improvement effect on the sound absorption and sound insulation performance is not obvious. At the same time, the crack resistance will also be affected, and the mortar is prone to cracks when shrinking or subjected to external forces. When the content is higher than 8 parts, too many fibers will entangle with each other during the mixing process, resulting in uneven mixing, affecting the fluidity and construction performance of the mortar, making the mortar difficult to construct, and may also reduce the strength of the mortar because too many fibers will disperse the bonding force of the cementitious material. In the examples, under different proportions of polypropylene fiber, the sound absorption coefficient, sound insulation amount, and compressive and bonding strengths can reach good levels, proving the scientific nature of this proportion.

[0032] 6. Expanded perlite (15 - 25 parts): Within this proportion range, expanded perlite can fully exert its properties. When the content of expanded perlite is less than 15 parts, the barrier effect of its internal porous structure on sound propagation is not obvious, and it cannot effectively reduce the density of the mortar and lighten the building load, thus not being able to well meet the requirements of building energy conservation and sound insulation. When the content is higher than 25 parts, it will greatly affect the strength of the mortar because too much expanded perlite will reduce the relative content of cementitious materials and other reinforcing materials, resulting in a decrease in compressive and bonding strength and not being able to meet the strength requirements of actual projects.

[0033] Finally, the present invention also provides the application of the gypsum-based composite sound insulation mortar in the sound insulation engineering of building walls, indoor partitions, and floors.

[0034] Furthermore, the application of the gypsum-based composite sound insulation mortar in the sound insulation engineering of building walls, indoor partitions, and floors is characterized in that it includes, but is not limited to, using the gypsum-based composite sound insulation mortar in building operations such as bonding between bricks, stones, and blocks, floor leveling, and building repair.

[0035] Based on the above technical solutions, the embodiments of the present invention can at least produce the following technical effects: (1) Excellent sound absorption and insulation performance: It has good absorption and barrier effects on sounds of different frequencies. In the frequency range of 100 - 5000 Hz, the average sound absorption coefficient is high, the sound insulation amount is excellent, effectively reducing indoor noise and significantly improving the acoustic environment quality.

[0036] (2) Good construction performance: It shows excellent construction performance and can be comparable to self-leveling materials. Its workability is extremely good. After adding water and stirring, it can quickly form a uniform and smooth slurry, having good fluidity like self-leveling materials and being able to automatically level under the action of gravity, greatly reducing the workload and difficulty of manual leveling.

[0037] (3) Outstanding fireproof performance: Using gypsum as the main raw material, it has excellent fireproof performance and meets the requirements of building fire safety. Detailed implementation manners

[0038] Now, various exemplary implementation manners of the present invention will be described in detail. This detailed description should not be regarded as a limitation of the present invention, but should be understood as a more detailed description of certain aspects, characteristics, and implementation schemes of the present invention.

[0039] It should be understood that the terms described in the present invention are only for describing specific embodiments and are not used to limit the present invention. Additionally, for the numerical ranges in the present invention, it should be understood that each intermediate value between the upper and lower limits of the range is also specifically disclosed. Each intermediate value within any stated value or stated range, as well as each smaller range between any other stated value or intermediate value within the stated range, is also included in the present invention. The upper and lower limits of these smaller ranges may be independently included or excluded from the range.

[0040] Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the art to which the present invention pertains. Although the present invention only describes preferred methods and materials, any methods and materials similar or equivalent to those described herein may also be used in the implementation or testing of the present invention. All documents mentioned in this specification are incorporated by reference to disclose and describe the methods and / or materials related to the documents. In case of conflict with any incorporated document, the content of this specification shall prevail.

[0041] Without departing from the scope or spirit of the present invention, various improvements and changes can be made to the specific embodiments of the present invention specification, which are obvious to those skilled in the art. Other embodiments obtained from the specification of the present invention are obvious to those skilled in the art. The specification and examples of the present invention are merely exemplary.

[0042] Regarding the use of "comprising", "including", "having", "containing", etc. herein, they are all open-ended terms, meaning including but not limited to.

[0043] Example 1

[0044] Raw materials: 50 parts of desulfurized gypsum, 15 parts of calcite, 7 parts of hydrated lime, 3 parts of redispersible latex powder, 5 parts of polypropylene fiber, 20 parts of vitrified microspheres, 0.5 part of hydroxypropyl methylcellulose, 0.3 part of sodium gluconate, 0.4 part of water reducer.

[0045] Preparation method: S1. Add desulfurized gypsum, calcite, hydrated lime, and vitrified microspheres to a dry powder mixer and stir for 5 - 10 minutes to preliminarily mix evenly. S2. Add polypropylene fiber and continue to stir for 3 - 5 minutes. S3. Add redispersible latex powder, hydroxypropyl methylcellulose, sodium gluconate, and polycarboxylate-based high-performance water reducer, and stir for 8 - 15 minutes to obtain a uniform gypsum-based composite sound insulation mortar.

[0046] Performance test: In the frequency range of 100 - 5000 Hz, the average sound absorption coefficient ≥ 0.4, the sound insulation amount ≥ 40 dB; the compressive strength is 5 MPa, the bonding strength is 0.6 MPa, and the fire resistance rating is Class A.

[0047] Example 2

[0048] Raw materials: 45 parts of desulfurized gypsum, 18 parts of calcite, 8 parts of hydrated lime, 4 parts of redispersible latex powder, 6 parts of polypropylene fiber, 22 parts of vitrified microspheres, 0.6 part of hydroxypropyl methylcellulose, 0.4 part of sodium gluconate, 0.3 part of water reducing agent.

[0049] Preparation method: S1. Add desulfurized gypsum, calcite, hydrated lime, and vitrified microspheres to a dry powder mixer and stir for 5 - 10 minutes to mix evenly initially. S2. Add polypropylene fiber and continue to stir for 3 - 5 minutes. S3. Add redispersible latex powder, hydroxypropyl methylcellulose, sodium gluconate, and polycarboxylate - based high - performance water reducing agent, and stir for 8 - 15 minutes to obtain uniform gypsum - based composite sound - insulating mortar.

[0050] Performance test: Average sound absorption coefficient 0.45, sound insulation amount 42 dB; Compressive strength 4.8 MPa, bonding strength 0.65 MPa, fire - proof grade A.

[0051] Example 3

[0052] Raw materials: 55 parts of desulfurized gypsum, 12 parts of calcite, 6 parts of hydrated lime, 2.5 parts of redispersible latex powder, 7 parts of polypropylene fiber, 18 parts of vitrified microspheres, 0.4 part of hydroxypropyl methylcellulose, 0.2 part of sodium gluconate, 0.5 part of water reducing agent.

[0053] Preparation method: S1. Add desulfurized gypsum, calcite, hydrated lime, and vitrified microspheres to a dry powder mixer and stir for 5 - 10 minutes to mix evenly initially. S2. Add polypropylene fiber and continue to stir for 3 - 5 minutes. S3. Add redispersible latex powder, hydroxypropyl methylcellulose, sodium gluconate, and polycarboxylate - based high - performance water reducing agent, and stir for 8 - 15 minutes to obtain uniform gypsum - based composite sound - insulating mortar.

[0054] Performance test: Average sound absorption coefficient 0.42, sound insulation amount 41 dB; Compressive strength 5.2 MPa, bonding strength 0.58 MPa, fire - proof grade A.

[0055] From Examples 1 - 3, the component compounding effect and examples are proved as follows: 1. Enhance sound absorption and insulation performance: Desulfurized gypsum, polypropylene fiber, and expanded perlite cooperate with each other to achieve a powerful sound absorption and insulation effect. Desulfurized gypsum, as the main binder, constructs the basic structure of the mortar, providing attachment and support for other components. Polypropylene fiber is fibrous and forms a three-dimensional network structure in the mortar. When sound propagates through the mortar and encounters these fibers, its propagation direction will be continuously changed, increasing the propagation path and the number of reflections, thus being absorbed and scattered multiple times. Expanded perlite is porous inside, and these pores can effectively block the propagation of sound, causing the sound to be continuously reflected and attenuated within the pores.

[0056] In Examples 1 - 3, in the frequency range of 100 - 5000 Hz, the average sound absorption coefficient of Example 1 is ≥0.4, and the sound insulation amount is ≥40 dB; the average sound absorption coefficient of Example 2 reaches 0.45, and the sound insulation amount is 42 dB; the average sound absorption coefficient of Example 3 is 0.42, and the sound insulation amount is 41 dB. These data fully demonstrate that the compounding of these three components significantly improves the sound absorption and insulation performance of the mortar.

[0057] 2. Improve bonding and crack resistance performance: Hydrated lime, re-dispersible latex powder, and polypropylene fiber act synergistically and have an important impact on the bonding and crack resistance performance of the mortar. Hydrated lime can enhance the bonding property of the mortar, making the mortar closely bond with the base material; at the same time, it can also improve the overall strength of the mortar and enhance its ability to resist external force damage. As a re-dispersible latex powder, the re-dispersible latex powder improves the bonding property and flexibility of the mortar, enabling the mortar to deform better without cracking when stressed, and enhancing the integrity and durability among the components of the mortar. Polypropylene fiber forms a reinforcing framework inside the mortar, further enhancing the crack resistance performance.

[0058] Judging from the data of the examples, the bonding strength of Example 1 reaches 0.6 MPa, that of Example 2 is 0.65 MPa, and that of Example 3 is 0.58 MPa. The compressive strength of Example 1 is 5 MPa, that of Example 2 is 4.8 MPa, and that of Example 3 is 5.2 MPa. These data show that after the compounding of the three components, while ensuring the bonding strength, the crack resistance performance is effectively improved, ensuring that the mortar will not easily crack or fall off during actual use.

[0059] 3. Optimize construction performance: The combined action of hydroxypropyl methylcellulose, sodium gluconate and water reducer greatly optimizes the construction performance of the mortar. Hydroxypropyl methylcellulose can retain the moisture in the mortar and delay the setting time of gypsum, enabling the mortar to maintain good plasticity and workability for a long time. Sodium gluconate, as a retarder, precisely adjusts the setting time of the mortar to avoid premature hardening of the mortar and provides sufficient time for construction operations. The water reducer (polycarboxylate-based high-performance water reducer) can reduce the water consumption during the mixing process of the mortar. On the premise of ensuring the fluidity of the mortar, it improves the strength and density of the mortar, and also indirectly enhances the sound insulation effect. In actual construction, this mortar exhibits excellent construction performance, with extremely good workability. After adding water and stirring, it can quickly form a uniform and smooth slurry, which has good fluidity like self-leveling materials and can automatically level under the action of gravity. In Examples 1 - 3, although the proportion of each component varies, this construction performance can be stably guaranteed, demonstrating the effectiveness and stability of this compound system.

[0060] The above are only the preferred embodiments of the present invention. It should be noted that for those of ordinary skill in the art, without departing from the inventive concept of the present invention, several modifications and improvements can be made, and these all belong to the protection scope of the present invention.

Claims

1. Gypsum-based composite sound insulation mortar, characterized in that: The invention comprises the following components in parts by weight: 40-60 parts of desulfurized gypsum, 10-20 parts of calcite, 5-10 parts of lime lime, 2-5 parts of redispersible latex powder, 3-8 parts of polypropylene fiber, 15-25 parts of vitrified microspheres, 0.2-0.8 parts of water retaining agent, 0.1-0.5 parts of retarder and 0.1-0.5 parts of water reducing agent.

2. The gypsum-based composite sound insulation mortar according to claim 1, characterized in that: The redispersible latex powder is one or more of ethylene / vinyl acetate copolymer, vinyl acetate / versatate copolymer, acrylic copolymer, styrene-acrylate, butadiene-styrene latex, ethylene-vinyl chloride-vinyl laurate, and ethylene-vinyl acetate-vinyl ester.

3. The gypsum-based composite sound insulation mortar according to claim 1, characterized in that: The water retaining agent is hydroxypropyl methylcellulose or methylcellulose.

4. The gypsum-based composite sound insulation mortar according to claim 1, characterized in that: The retarder is sodium gluconate, and the water reducer is a polycarboxylic acid-based high-performance water reducer.

5. The method for preparing the gypsum-based composite sound insulation mortar according to any one of claims 1 to 4, characterized in that: The following steps are involved: S1. Add desulfurized gypsum, calcite, lime lime and vitrified microspheres into a dry powder mixer and stir for 5-10 minutes to mix them evenly. S2. Add polypropylene fiber and continue stirring for 3-5 minutes; S3. Add redispersible latex powder, water retaining agent, retarder and water reducing agent, stir for 8-15 minutes to obtain a uniform gypsum-based composite sound insulation mortar.

6. Application of the gypsum-based composite sound insulation mortar according to any one of claims 1 to 4 in building wall sound insulation, indoor partition sound insulation and ground sound insulation projects.

7. The use of the gypsum-based composite sound insulation mortar according to claim 6 in building wall sound insulation, indoor partition sound insulation and ground sound insulation engineering, characterized in that: This includes, but is not limited to, using gypsum-based composite sound insulation mortar in construction operations such as bonding bricks, stones, and blocks, leveling the ground, and repairing buildings.