High-wear-resistance thermal insulation mortar and preparation method thereof

Abstract

The invention relates to the technical field of mortar, and particularly discloses high-wear-resistance thermal insulation mortar and a preparation method thereof. The high-wear-resistance thermal insulation mortar provided by the invention is prepared from the following components in parts by weight: 30 to 40 parts of sulphoaluminate cement, 35 to 50 parts of Portland cement, 15 to 25 parts of modified ceramsite, 5 to 10 parts of expanded perlite, 20 to 35 parts of wear-resistant filler and 5 to 10 parts of silicon dioxide aerogel, a preparation method of the modified ceramsite comprises the following steps: soaking ceramsite in a silane coupling agent solution with the temperature of 80-90 DEG C and the mass concentration of 0.5-1%, and drying to obtain the modified ceramsite. Further, the silane coupling agent is KH550, the soaking time is 5-8 hours, and the drying temperature is 100-120 DEG C; the invention further provides a preparation method of the high-wear-resistance thermal insulation mortar. The high-wear-resistance thermal insulation mortar provided by the invention can simultaneously have thermal insulation and wear resistance, and has a very good comprehensive use effect.

Description

Technical Field

[0001] This application relates to the technical field of mortar, and specifically relates to a highly wear-resistant thermal insulation mortar and a preparation method thereof. Background Art

[0002] As an important building energy-saving material, thermal insulation mortar can improve the energy utilization efficiency by reducing the heat conduction of buildings, thereby reducing energy consumption and improving the living environment, and has been widely used in the building interior and exterior wall thermal insulation systems. With the continuous improvement of building energy-saving requirements, the research and application of thermal insulation mortar have become an important research direction in the construction industry.

[0003] In order to improve the performance of traditional thermal insulation mortar, various means are usually adopted in the prior art. For example, adding wear-resistant agents to enhance the surface wear resistance of the mortar, or introducing reinforcing fibers to improve the overall strength and crack resistance, and also by optimizing the formula of inorganic thermal insulation materials, such as adding lightweight materials such as expanded perlite, to improve the thermal insulation performance. However, the above methods still have certain limitations. For example, simply adding wear-resistant agents or reinforcing fibers can improve the wear resistance, but often lead to an increase in the thermal conductivity coefficient and sacrifice the thermal insulation performance; special thermal insulation materials used in order to pursue high thermal insulation performance will result in insufficient strength of the mortar. That is, the above methods often can only optimize the single performance of the mortar, and it is difficult to take into account both thermal insulation and wear resistance at the same time, which greatly limits its scope of use.

[0004] Therefore, how to effectively improve the wear resistance of the mortar while ensuring the thermal insulation performance has become a technical problem to be solved urgently. Summary of the Invention

[0005] In order to overcome the problem that the existing mortar is difficult to take into account both thermal insulation and wear resistance at the same time, this application provides a highly wear-resistant thermal insulation mortar and a preparation method thereof.

[0006] The highly wear-resistant thermal insulation mortar provided by this application adopts the following technical scheme: A highly wear-resistant thermal insulation mortar, comprising the following components in parts by weight: 30-40 parts of sulfoaluminate cement, 35-50 parts of portland cement, 15-25 parts of modified ceramsite, 5-10 parts of expanded perlite, 20-35 parts of wear-resistant filler, and 5-10 parts of silica aerogel; the preparation method of the modified ceramsite is: soaking the ceramsite in a silane coupling agent solution at 80-90 °C and with a mass concentration of 0.5-1%, and drying to obtain the modified ceramsite.

[0007] The present application provides a highly wear-resistant thermal insulation mortar, which can take into account both the thermal insulation and wear resistance of the mortar, achieving a significant improvement in the comprehensive performance of the mortar. Specifically: The compound use of sulfoaluminate cement and Portland cement not only enhances the early strength of the matrix, but also improves the later stability, providing a solid foundation for the overall mortar performance. The modified ceramsite can improve the overall strength and thermal insulation performance of the mortar. Expanded perlite has excellent thermal insulation performance and can effectively reduce the thermal conductivity. The wear-resistant filler can endow the surface of the mortar with excellent anti-wear ability and effectively resist the influence of external mechanical stress. The addition of silica aerogel endows the mortar with excellent thermal insulation performance. Its extremely low thermal conductivity can significantly reduce heat transfer and meet the building energy-saving requirements. Through the reasonable proportioning and interaction among multiple components, the present application not only overcomes the problem that it is difficult to balance thermal insulation and wear resistance in traditional materials, but also greatly improves the overall service life of the mortar, providing a more reliable solution for the building interior and exterior wall thermal insulation system.

[0008] In the present application, the ceramsite is chemically pretreated with a silane coupling agent. On the one hand, it can enhance the surface activity of the ceramsite, significantly improve the interfacial bonding strength between it and the cement matrix, effectively improve the dispersibility and compatibility of the ceramsite in the mortar system, thereby enhancing the overall mechanical properties and wear resistance of the mortar, and at the same time reducing the cracking risk caused by interfacial defects; on the other hand, by controlling the mass concentration of the silane coupling agent solution within the above range, a very thin organic film can be formed on the surface of the ceramsite by KH550. This organic film can further block heat conduction, thereby achieving a good thermal insulation effect; in addition, it should be noted that: if the mass concentration of the silane coupling agent solution is too high, KH550 will penetrate into the interior of the ceramsite, thereby destroying the porous structure of the ceramsite, reducing the porosity of the ceramsite and increasing the density, which will further promote heat transfer and lead to a decrease in thermal insulation performance. Therefore, in the present application, the ceramsite is modified with KH550, and further controlling the mass concentration of the silane coupling agent solution within the above range can improve the overall mechanical properties and wear resistance of the mortar while also improving the thermal insulation performance to a certain extent.

[0009] In some embodiments, the mass concentration of the silane coupling agent solution can be 0.5-0.8% or 0.8-1%.

[0010] In a specific embodiment, the mass concentration of the silane coupling agent solution can be 0.5%, 0.8% or 1%.

[0011] In some embodiments, the weight portion of the modified ceramsite can be 150-200 parts or 200-250 parts.

[0012] In a specific embodiment, the weight portion of the modified ceramsite can also be 150 parts, 200 parts or 250 parts.

[0013] In some embodiments, the weight parts of the wear-resistant filler can be 200 - 300 parts or 300 - 350 parts.

[0014] In a specific embodiment, the weight parts of the wear-resistant filler can also be 200 parts, 300 parts or 350 parts.

[0015] In some embodiments, the weight parts of the silica aerogel can be 50 - 80 parts or 80 - 100 parts.

[0016] In a specific embodiment, the weight parts of the silica aerogel can also be 50 parts, 80 parts or 100 parts.

[0017] Optionally, the silane coupling agent is KH550, the soaking time is 5 - 8 h, and the drying temperature is 100 - 120 °C.

[0018] Optionally, the particle size of the modified ceramsite is 0.5 - 2 mm.

[0019] Optionally, the wear-resistant filler is selected from one or more of granite, basalt fiber, quartz sand, zircon sand, silicon carbide and titanium carbide.

[0020] Optionally, the wear-resistant filler is a mixture of basalt fiber, zircon sand and titanium carbide.

[0021] Optionally, the weight ratio of the basalt fiber, zircon sand and titanium carbide is 1:(0.5 - 1.5):(0.1 - 0.3).

[0022] By using the above materials as the wear-resistant filler, this application can significantly improve the wear resistance of the mortar while ensuring excellent thermal insulation performance. Specifically, basalt fiber has the characteristics of high strength and high hardness, and it can form a network structure in the mortar to prevent the expansion of mortar cracks, significantly improving the overall strength and toughness of the mortar, and thus enhancing the wear resistance of the mortar; zircon sand can provide good hardness and wear resistance, enhancing the anti-wear ability of the mortar surface; titanium carbide, as a high-performance hard material, can improve the wear resistance and impact resistance of the mortar. Through experimental exploration, it is found that by selecting the above three substances as the wear-resistant filler of the mortar and controlling the weight ratio of the three within the above range, the synergistic effect among the three can be effectively exerted, and the overall wear resistance of the mortar can be greatly improved without sacrificing the thermal insulation effect.

[0023] In some embodiments, the weight ratio of the basalt fiber, zircon sand and titanium carbide can be 1:(0.5 - 1):0.2, 1:(1 - 1.5):0.2, 1:1:(0.1 - 0.2) or 1:1:(0.2 - 0.3).

[0024] In a specific embodiment, the weight ratio of the basalt fiber, zircon sand and titanium carbide can also be 1:0.5:0.2, 1:1:0.2, 1:1.5:0.2, 1:1:0.1 or 1:1:0.3.

[0025] Optionally, the high wear-resistant thermal insulation mortar further includes 1 - 1.5 parts of water reducing agent and 0.5 - 1 part of water repellent.

[0026] In a second aspect, the present application provides a method for preparing a high wear-resistant thermal insulation mortar.

[0027] A method for preparing a high wear-resistant thermal insulation mortar includes the following steps: First, mix the sulfoaluminate cement, Portland cement, ceramsite, expanded perlite and silica aerogel, add water and stir evenly; then add the wear-resistant filler and other components, and continue to stir evenly to obtain the high wear-resistant thermal insulation mortar.

[0028] In summary, the present application has the following beneficial effects: 1. The present application uses sulfoaluminate cement, Portland cement, modified ceramsite, expanded perlite, wear-resistant filler and silica aerogel to prepare a high wear-resistant thermal insulation mortar, which solves the problem that it is difficult to balance heat preservation and wear resistance in traditional materials, greatly improves the overall service life of the mortar, and provides a more reliable solution for the building interior and exterior wall thermal insulation system.

[0029] 2. The present application uses a silane coupling agent with a specific concentration to modify the ceramsite. The prepared ceramsite can improve the overall mechanical properties and wear resistance of the mortar. At the same time, the organic film on the surface of the modified ceramsite can prevent heat conduction, so that the mortar has a good heat preservation effect.

[0030] 3. The present application further uses a mixture of basalt fiber, zircon sand and titanium carbide as the wear-resistant filler, and controls the weight ratio of the three within the range of 1:(0.5 - 1.5):(0.1 - 0.3), which can greatly improve the wear resistance of the mortar without sacrificing the heat preservation effect, so that the wear amount of the high wear-resistant thermal insulation mortar after the wear test is as low as 0.05 g / cm 2 and below. Specific embodiments

[0031] The present application provides a highly wear-resistant thermal insulation mortar, which comprises the following components in parts by weight: 30-40 parts of sulfoaluminate cement, 35-50 parts of portland cement, 15-25 parts of modified ceramsite, 5-10 parts of expanded perlite, 20-35 parts of wear-resistant filler, 5-10 parts of silica aerogel, 1-1.5 parts of water reducer, and 0.5-1 part of water repellent. Among them, the preparation method of the modified ceramsite is as follows: soaking the ceramsite in a silane coupling agent solution with a temperature of 80-90 °C and a mass concentration of 0.5-1% for 5-8 h, and drying it at 100-120 °C to obtain the modified ceramsite. The wear-resistant filler is selected from one or more of granite, basalt fiber, quartz sand, zircon sand, silicon carbide, and titanium carbide. Further, the wear-resistant filler is a mixture of basalt fiber, zircon sand, and titanium carbide. Still further, the weight ratio of basalt fiber, zircon sand, and titanium carbide is 1:(0.5-1.5):(0.1-0.3).

[0032] The preparation method of the highly wear-resistant thermal insulation mortar provided by the present application comprises the following steps: firstly, mixing sulfoaluminate cement, portland cement, ceramsite, expanded perlite, and silica aerogel, adding water and stirring evenly; then adding the wear-resistant filler and other components, and continuing to stir evenly to obtain the highly wear-resistant thermal insulation mortar.

[0033] In the examples of the present application, the silane coupling agent is KH550; the particle size of the ceramsite is 0.5-2 mm; the expanded perlite is purchased from Shijiazhuang Yitian Mineral Products Co., Ltd.; the basalt fiber is purchased from Changzhou Tianyi Engineering Fiber Co., Ltd.; the zircon sand is purchased from Qinglong Minerals, with a mesh number of 80-120; the quartz sand is purchased from Naiman Banner Zhongyi Sand Industry Co., Ltd., with a mesh number of 20-40; the titanium carbide is purchased from Qinghe County Chaotai Metal Materials Co., Ltd., with a mesh number of 300; the silica aerogel is purchased from Langmiao Environmental Protection Technology (Tianjin) Co., Ltd., and the thermal conductivity is 0.013 W / (m·K). The raw materials, reagents, solvents, etc. used in the present application can all be obtained through commercial purchase.

[0034] The present application will be further described in detail below with reference to preparation examples, examples, and performance detection tests.

[0035] Preparation Example 1 Preparation Example 1 provides a modified ceramsite.

[0036] The preparation method of the above-mentioned modified ceramsite is as follows: soaking the ceramsite in an aqueous solution of KH550 with a constant temperature of 80 °C and a mass concentration of 0.8%, taking it out after soaking for 8 h, and then drying it at 110 °C for 2 h to obtain the modified ceramsite.

[0037] Preparation Example 2 Preparation Example 2 provides a modified ceramsite.

[0038] The difference between the above Preparation Example and Preparation Example 1 is that the mass concentration of the KH550 aqueous solution is 0.5%.

[0039] Preparation Example 3 Preparation Example 3 provides a modified ceramsite.

[0040] The difference between the above Preparation Example and Preparation Example 1 is that the mass concentration of the KH550 aqueous solution is 1%.

[0041] Comparative Preparation Example 1 Comparative Preparation Example 1 provides a modified ceramsite.

[0042] The difference between the above Comparative Preparation Example and Preparation Example 1 is that the mass concentration of the KH550 aqueous solution is 0.2%.

[0043] Comparative Preparation Example 2 Comparative Preparation Example 2 provides a modified ceramsite.

[0044] The difference between the above Comparative Preparation Example and Preparation Example 1 is that the mass concentration of the KH550 aqueous solution is 1.5%.

[0045] Examples 1 - 3 Examples 1 - 3 respectively provide a high wear-resistant thermal insulation mortar.

[0046] The difference between the above Examples is that the modified ceramsites used in Examples 1 - 3 are respectively from Preparation Examples 1 - 3.

[0047] The preparation method of the above high wear-resistant thermal insulation mortar includes the following steps: First, mix 350 g of sulfoaluminate cement, 400 g of portland cement, 200 g of modified ceramsite, 80 parts of expanded perlite and 80 g of silica aerogel, add 160 g of water and stir evenly; then add 300 g of basalt fiber, 12 g of polycarboxylate water reducer and 8 g of sodium methyl silicate water repellent, and continue to stir evenly to obtain the high wear-resistant thermal insulation mortar.

[0048] Examples 4 - 9 Examples 4 - 9 respectively provide a high wear-resistant thermal insulation slurry.

[0049] The difference between the above Examples and Example 1 is that the addition amounts of the modified ceramsite, wear-resistant filler and silica aerogel are as shown in Table 1 below.

[0050] Table 1 Addition amounts of modified ceramsite, wear-resistant filler and silica aerogel in Examples 4 - 9 Examples 10 - 17 Examples 10 - 17 respectively provide a high wear-resistant thermal insulation slurry.

[0051] The differences between the above embodiments and Embodiment 1 are as follows: the types and ratios of wear-resistant fillers are shown in Table 2 below.

[0052] Table 2 Types and ratios of wear-resistant fillers in Embodiment 1 and Embodiments 10 - 17 Comparative Examples 1 - 2 Comparative Examples 1 - 2 respectively provide a highly wear-resistant thermal insulation mortar.

[0053] The differences between the above comparative examples and Embodiment 1 are as follows: the modified ceramsites used in Comparative Examples 1 - 2 are respectively from Comparative Preparation Examples 1 - 2.

[0054] Comparative Example 3 Comparative Example 3 provides a highly wear-resistant thermal insulation mortar.

[0055] The differences between the above comparative example and Embodiment 1 are as follows: the modified ceramsite is replaced with ceramsite.

[0056] Performance detection test The thermal insulation and wear resistance of the highly wear-resistant thermal insulation mortars obtained in Embodiments 1 - 17 and Comparative Examples 1 - 3 were detected, and the results are shown in Table 3 below.

[0057] Table 3 Performance detection results of the highly wear-resistant thermal insulation mortars obtained in Embodiments 1 - 17 and Comparative Examples 1 - 3 According to the detection results in Table 3, it can be known that the thermal conductivity of the highly wear-resistant thermal insulation mortar obtained in Embodiments 1 - 17 of the present application is 0.09 - 0.12 W / (m·K), and the wear amount after the wear resistance test is 0.04 - 0.10 g / cm 2 ; while the thermal conductivity of the highly wear-resistant thermal insulation mortar obtained in Comparative Examples 1 - 3 is as high as 0.15 - 0.18 W / (m·K), and the wear amount after the wear resistance test is as high as 0.06 - 0.14 g / cm 2 . Therefore, it shows that the present application uses modified ceramsite to prepare a highly wear-resistant thermal insulation mortar, and controls the mass concentration of the silane coupling agent solution used in the preparation method of the modified ceramsite within the range of 0.5 - 1%, and a highly wear-resistant thermal insulation mortar with good comprehensive performance of wear resistance and thermal insulation can be obtained.

[0058] Further comparing the detection results of Embodiment 1 and Embodiments 10 - 17, it can be known that Embodiment 1 only uses basalt fiber as the wear-resistant filler, and the wear amount of the obtained highly wear-resistant thermal insulation mortar after the wear resistance test is 0.08 g / cm 2; In Examples 15 - 17, basalt fiber, zircon sand, and titanium carbide with a weight ratio of 1:2:1, or basalt fiber, quartz sand, and titanium carbide with a weight ratio of 1:1:0.2, or basalt fiber, quartz sand, and silicon carbide with a weight ratio of 1:1:0.2 were used as wear-resistant fillers. The wear amount of the obtained high wear-resistant thermal insulation mortar after the wear test was 0.06 - 0.08 g / cm 2 ; In Examples 10 - 14, basalt fiber, zircon sand, and titanium carbide with a weight ratio of 1:(0.5 - 1.5):(0.1 - 0.3) were used as wear-resistant fillers. The wear amount of the obtained high wear-resistant thermal insulation mortar after the wear test was 0.04 - 0.05 g / cm 2 (≤0.05 g / cm 2 ). Therefore, it shows that further using basalt fiber, zircon sand, and titanium carbide with a weight ratio of 1:(0.5 - 1.5):(0.1 - 0.3) as wear-resistant fillers in this application, the obtained high wear-resistant thermal insulation mortar has better wear resistance.

[0059] Although the present invention has been described in detail with general descriptions and specific embodiments above, based on the present invention, some modifications or improvements can be made, which are obvious to those skilled in the art. Therefore, these modifications or improvements made without departing from the spirit of the present invention all fall within the scope of the present invention claimed.

Claims

1. A highly wear-resistant thermal insulation mortar, characterized in that, It comprises the following components in parts by weight: 30-40 parts of sulfoaluminate cement, 35-50 parts of Portland cement, 15-25 parts of modified ceramsite, 5-10 parts of expanded perlite, 20-35 parts of wear-resistant filler, and 5-10 parts of silica aerogel; The preparation method of the modified ceramsite is as follows: The ceramsite is immersed in a silane coupling agent solution at 80-90 °C with a mass concentration of 0.5-1%, and then dried to obtain the modified ceramsite.

2. The highly wear-resistant thermal insulation mortar according to claim 1, wherein The silane coupling agent is KH550, the immersion time is 5-8 h, and the drying temperature is 100-120 °C.

3. The highly wear-resistant thermal insulation mortar according to claim 1, wherein The particle size of the modified ceramsite is 0.5-2 mm.

4. The high wear-resistant thermal insulation mortar according to claim 1, wherein, The wear-resistant filler is selected from one or more of granite, basalt fiber, quartz sand, zircon sand, silicon carbide, and titanium carbide.

5. The highly wear-resistant thermal insulation mortar according to claim 1, wherein The wear-resistant filler is a mixture of basalt fiber, zircon sand, and titanium carbide.

6. The highly wear-resistant thermal insulation mortar according to claim 5, wherein, The weight ratio of the basalt fiber, zircon sand, and titanium carbide is 1:(0.5-1.5):(0.1-0.3).

7. The highly wear-resistant thermal insulation mortar according to any one of claims 1-6, characterized in that The high wear-resistant thermal insulation mortar further comprises 1-1.5 parts of water reducer and 0.5-1 part of water repellent.

8. The preparation method of the highly wear-resistant thermal insulation mortar according to any one of claims 1-7, characterized in that, It includes the following steps: First, mix the sulfoaluminate cement, Portland cement, ceramsite, expanded perlite, and silica aerogel, add water and stir evenly; then add the wear-resistant filler and other components, and continue to stir evenly to obtain the high wear-resistant thermal insulation mortar.

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