An antistatic non-sparking self-leveling mortar material and a preparation method thereof

Abstract

The present application relates to the technical field of self-leveling mortar, and particularly relates to an antistatic non-ignition self-leveling mortar material and a preparation method thereof.The antistatic non-ignition self-leveling mortar material comprises, by mass fraction, 160-320 of cementing material, 200-400 of sand, 10-20 of fly ash, 1-10 of lime powder, 10-30 of antistatic fiber, 110-230 of composite fiber, 1-3 of polycarboxylate superplasticizer, 1-2 of cellulose ether, 1-4 of retarder, 0.5-1 of defoaming agent, 1-2 of latex powder, 1-2 of shrinkage-reducing agent, 1-2 of early strength agent, and 120-180 of water;the composite fiber is subjected to plasma treatment with basalt fiber, then the non-ignition filler is added and stirred, and then ultrasonic treatment is performed to obtain the composite fiber;the non-ignition filler comprises limestone powder, nano silicon dioxide and KH550 coupling agent;the mass ratio of the limestone powder, the nano silicon dioxide and the KH550 coupling agent is 100:1-5:1-2.

Description

Technical Field

[0001] This invention relates to the field of self-leveling mortar technology, and in particular to an antistatic, non-sparking self-leveling mortar material and its preparation method. Background Technology

[0002] Self-leveling mortar, as an important material for modern building floor construction, is widely used in various construction projects due to its excellent flowability and self-leveling properties. Cement-based self-leveling mortar is composed of cementitious materials, fine aggregates, fillers, and additives. When mixed with water, it exhibits excellent flowability, allowing it to spread quickly and form a highly smooth base surface. Its advantages, such as high early strength, fast construction speed, and low labor intensity, make it an important development direction in building floor construction.

[0003] However, self-leveling mortar still has many problems in practical applications, especially in flammable and explosive environments, where its safety performance is particularly lacking. Ignition is a dangerous phenomenon that may occur when self-leveling mortar encounters impact or friction. Essentially, when a hard object impacts or rubs against it, less energy is lost, and the remaining energy instantly accumulates in a localized area of ​​microparticles, causing the energy of the microparticles to suddenly increase, resulting in high-temperature luminescence.

[0004] Meanwhile, the sparks generated by electrostatic discharge are also a potential safety hazard. This is because when objects with different electrostatic potentials approach each other, the high voltage breaks down the air, causing air molecules to ionize and form an electric arc. If the energy of the electric arc reaches a certain level, it will produce an electric spark, which can easily cause an explosion or fire, posing a serious threat to personal safety and property.

[0005] Existing self-leveling mortars cannot achieve a true self-leveling effect. At the same time, the impact resistance of the mortar after curing is insufficient, and it is easy to crack or peel off when subjected to external impact, affecting its service life and safety. Moreover, the cured mortar still has a high risk of ignition when it is subjected to impact or friction, and its anti-static properties are unstable, which cannot meet the safety requirements of flammable and explosive environments.

[0006] These problems severely limit the application of self-leveling mortar in flammable and explosive environments, high-requirement industrial flooring, and other fields. Therefore, developing a self-leveling mortar material with excellent flow properties, non-sparking properties, stable antistatic properties, and strong impact resistance has become an urgent need. Summary of the Invention

[0007] The purpose of this invention is to address the shortcomings of existing technologies by proposing an antistatic, non-sparking self-leveling mortar material and its preparation method.

[0008] An antistatic, non-sparking self-leveling mortar material, the raw materials of which include, by weight: 160-320 parts cementitious material, 200-400 parts sand, 10-20 parts fly ash, 1-10 parts lime powder, 10-30 parts antistatic fiber, 110-230 parts composite fiber, 1-3 parts polycarboxylate superplasticizer, 1-2 parts cellulose ether, 1-4 parts retarder, 0.5-1 part defoamer, 1-2 parts latex powder, 1-2 parts shrinkage reducer, 1-2 parts early strength agent, and 120-180 parts water.

[0009] The composite fiber is obtained by plasma treatment of basalt fiber, followed by stirring with non-sparking filler, and then ultrasonic treatment; the mass ratio of basalt fiber to non-sparking filler is 1-3:10-20.

[0010] The non-sparking filler includes: limestone powder, nano silica, and KH550 coupling agent; the mass ratio of limestone powder, nano silica, and KH550 coupling agent is 100:1-5:1-2.

[0011] The antistatic fiber is prepared by the following steps: graphene, polypyrrole, and dispersant are added to water and stirred evenly to obtain pretreated graphene; cellulose pulp is added to ionic liquid and stirred evenly, pretreated graphene is added to it and stirred evenly, and then melt-extruded.

[0012] Preferably, the cementing material includes: ordinary Portland cement, aluminum sulfate cement, and anhydrite, with the mass ratio of ordinary Portland cement, aluminum sulfate cement, and anhydrite being 40-60:100-200:20-60.

[0013] Preferably, the sand comprises: coarse sand with a particle size of 0.3-0.6 mm and fine sand with a particle size of 0.1-0.2 mm, wherein the mass ratio of coarse sand to fine sand is 1-2:1-2.

[0014] Preferably, the plasma treatment time is 5-10 min, the working gas for plasma treatment is air, the air flow rate during plasma treatment is 0.3-3 L / min, and the discharge power is 200-250 W.

[0015] Preferably, the ionic liquid is any one of 1-ethyl-3-methylimidazolium bis(trifluoromethanesulfonyl)imine salt ionic liquid, 1-butyl-3-methylimidazolium chloride ionic liquid, 1-allyl-3-methylimidazolium chloride ionic liquid, 1-(2-hydroxyethyl)-3-methylimidazolium chloride ionic liquid, and 1-ethyl-3-methylimidazolium chloride ionic liquid.

[0016] More preferably, the mass ratio of graphene, polypyrrole, dispersant, cellulose pulp, and ionic liquid is 1-3:1-2:1-2:10-20:30-50.

[0017] More preferably, the dispersant is polyvinylpyrrolidone.

[0018] Preferably, the defoamer is a polyether defoamer.

[0019] Preferably, the retarder is sodium gluconate.

[0020] Preferably, the early strength agent is lithium sulfate.

[0021] Preferably, the cellulose ether includes at least one of hydroxypropyl methylcellulose ether and hydroxyethyl methylcellulose ether.

[0022] Preferably, the latex powder is an ethylene-vinyl acetate copolymer powder.

[0023] The preparation method of the above-mentioned antistatic, non-sparking self-leveling mortar material includes the following steps:

[0024] S1. Mix the cementitious materials, sand, fly ash, antistatic fiber, and lime powder for 1-5 minutes to obtain a mixture.

[0025] S2. Stir the polycarboxylate superplasticizer, cellulose ether, retarder, defoamer, latex powder, shrinkage reducer, and early strength agent for 1-3 minutes. Add the mixture and composite fiber and continue stirring for 1-3 minutes. Then add water and stir for 1-3 minutes.

[0026] Beneficial effects:

[0027] This invention uses ordinary silicate cement and low-alkalinity aluminum sulfate cement as a compound. The aluminum sulfate cement will form a colloid with the cement hydration products in the mortar. This not only fills the micro gaps generated during the cement hardening process, significantly improving the density and impermeability of the material, but also its low-alkalinity characteristics can effectively prevent alkali-aggregate reaction damage, thus ensuring early strength development and improving long-term durability.

[0028] In the non-sparking filler used in this invention, the surface of limestone powder is coated with KH550 coupling agent and combined with nano-silica. The introduction of nano-silica can enhance the toughness and deformability of limestone powder, enabling it to absorb energy through plastic deformation when impacted, thus avoiding local energy accumulation and high-temperature sparking. At the same time, KH550 coupling agent improves the interfacial bonding between inorganic filler and organic matrix, thereby improving overall impact resistance.

[0029] This invention involves treating basalt fibers with low-temperature plasma, which not only significantly increases the specific surface area but also introduces active groups such as hydroxyl and carbonyl groups, significantly improving the bonding strength with non-sparking fillers. This forms a three-dimensional network in the mortar, effectively preventing static electricity buildup and enhancing the interfacial bonding between the fibers and the matrix, thereby greatly improving the impact resistance of the composite material.

[0030] In the antistatic fiber used in this invention, graphene and polypyrrole are combined. Graphene provides a continuous conductive path, enabling rapid charge conduction, while polypyrrole enhances conductivity stability. The combination results in low surface resistance and stable conductivity of the fiber. The antistatic fiber, together with the composite fiber, forms a fiber skeleton in the mortar, significantly improving the stability of the material's antistatic performance. By optimizing the particle size distribution and additive system, the material's flowability can reach 180±5mm, meeting the requirements for self-leveling construction without the need for manual leveling. Simultaneously, it exhibits excellent impact resistance, low ignition risk, and stable antistatic performance, meeting the safety requirements for flammable and explosive environments. Attached Figure Description

[0031] Figure 1 This is a comparison chart of the flowability of the self-leveling mortar materials obtained in Example 5 and Comparative Examples 1-3.

[0032] Figure 2 This is a comparison chart of the compressive strength of the self-leveling mortar materials obtained in Example 5 and Comparative Examples 1-3.

[0033] Figure 3 The diagram shows a comparison of the flexural strength of the self-leveling mortar materials obtained in Example 5 and Comparative Examples 1-3.

[0034] Figure 4 The surface resistance comparison diagrams are for the self-leveling mortar materials obtained in Example 5 and Comparative Examples 1-3. Detailed Implementation

[0035] The present invention will be further explained below with reference to specific embodiments.

[0036] The calcium hydroxide content in the lime powder used below is not less than 92%, and the particle size is 150-300 mesh. The polycarboxylate superplasticizer SPT-160UX used below was purchased from Guangzhou Chaosu Building Materials Co., Ltd. The polyether defoamer used below was purchased from Shandong Luderui New Materials Co., Ltd. The ethylene-vinyl acetate copolymer latex powder used below was purchased from Shandong Fuliyuan Chemical Co., Ltd. The shrinkage reducer used below was purchased from Nanjing Xinyi Synthetic Technology Co., Ltd., model ASA815. The basalt fiber used below has a length of 6 mm.

[0037] Example 1

[0038] An antistatic, non-sparking self-leveling mortar material, the raw materials of which include: 16kg of cementitious material, 20kg of sand, 1kg of Grade I fly ash, 100g of lime powder, 1kg of antistatic fiber with a diameter of 0.5±0.1mm, 11kg of composite fiber, 100g of polycarboxylate superplasticizer SPT-160UX, 100g of hydroxypropyl methylcellulose ether, 100g of sodium gluconate, 50g of polyether defoamer, 100g of ethylene-vinyl acetate copolymer latex powder, 100g of shrinkage reducer, 100g of lithium sulfate, and 12kg of water.

[0039] The cementitious material is composed of P·Ⅱ52.5R silicate cement, L·SAC 42.5 low-alkalinity aluminum sulfate cement, and anhydrite in a mass ratio of 2:5:1. The sand is composed of coarse sand with a particle size of 0.3-0.6mm and fine sand with a particle size of 0.1-0.2mm in a mass ratio of 1:1.

[0040] The composite fiber is obtained by plasma treatment (using air as the working gas, with an air flow rate of 0.5L / min and a discharge power of 200W) for 5 minutes, followed by the addition of 10kg of non-sparking filler and stirring for 5 minutes at a stirring speed of 100r / min, and then ultrasonic treatment (with an ultrasonic frequency of 80kHz) for 10 minutes.

[0041] The non-sparking filler is made by heating 10 kg of limestone powder to 90°C to remove moisture, adding 100 g of nano silica and 100 g of KH550 coupling agent, grinding at 1000 r / min for 10 min, cooling to room temperature, and passing through a 200 mesh sieve.

[0042] The antistatic fiber is prepared by the following steps: 100g of graphene, 100g of polypyrrole, and 100g of polyvinylpyrrolidone are added to 500g of water and stirred evenly to obtain pretreated graphene; 1kg of cellulose pulp is added to 3kg of 1-butyl-3-methylimidazolium chloride ionic liquid and stirred evenly, then the pretreated graphene is added and stirred evenly, and finally the mixture is added to a twin-screw extruder for melt extrusion.

[0043] The preparation method of the above-mentioned antistatic, non-sparking self-leveling mortar material includes the following steps:

[0044] S1. Add cementitious materials, sand, Class I fly ash, antistatic fiber, and lime powder to a mixer and stir for 1 minute to obtain a mixture;

[0045] S2. Add polycarboxylate superplasticizer SPT-160UX, hydroxypropyl methylcellulose ether, sodium gluconate, polyether defoamer, ethylene-vinyl acetate copolymer latex powder, shrinkage reducer, and lithium sulfate to a mixer and stir for 1 minute. Add the mixture and composite fiber and continue stirring for 1 minute. Then add water and stir for 1 minute.

[0046] Example 2

[0047] An antistatic, non-sparking self-leveling mortar material comprises the following raw materials: 32 kg of cementitious material, 40 kg of sand, 2 kg of Grade I fly ash, 1 kg of lime powder, 3 kg of antistatic fiber with a diameter of 0.5 ± 0.1 mm, 23 kg of composite fiber, 300 g of polycarboxylate superplasticizer SPT-160UX, 200 g of hydroxyethyl methyl cellulose ether, 400 g of sodium gluconate, 100 g of polyether defoamer, 200 g of ethylene-vinyl acetate copolymer latex powder, 200 g of shrinkage reducer, 200 g of lithium sulfate, and 18 kg of water.

[0048] The cementitious material is composed of P·Ⅱ52.5R silicate cement, L·SAC 42.5 low-alkalinity aluminum sulfate cement, and anhydrite in a mass ratio of 3:10:3. The sand is composed of coarse sand with a particle size of 0.3-0.6mm and fine sand with a particle size of 0.1-0.2mm in a mass ratio of 1:1.

[0049] The composite fiber is obtained by plasma treatment (using air as the working gas, with an air flow rate of 3L / min and a discharge power of 250W) for 10 minutes, followed by the addition of 20kg of non-sparking filler and stirring for 15 minutes at a stirring speed of 300r / min, and then ultrasonic treatment (with an ultrasonic frequency of 90kHz) for 30 minutes.

[0050] The non-sparking filler is made by heating 10 kg of limestone powder to 100°C to remove moisture, adding 500 g of nano silica and 200 g of KH550 coupling agent, grinding at 1500 r / min for 20 min, cooling to room temperature, and passing through a 250 mesh sieve.

[0051] The antistatic fiber is prepared by the following steps: 300g of graphene, 200g of polypyrrole, and 200g of polyvinylpyrrolidone are added to 1000g of water and stirred evenly to obtain pretreated graphene; 2000g of cellulose pulp is added to 5000g of 1-allyl-3-methylimidazolium chloride ionic liquid and stirred evenly; the pretreated graphene is added to the mixture and stirred evenly; and the mixture is then melt-extruded using a twin-screw extruder.

[0052] The preparation method of the above-mentioned antistatic, non-sparking self-leveling mortar material includes the following steps:

[0053] S1. Add cementitious materials, sand, Class I fly ash, antistatic fiber, and lime powder to a mixer and stir for 5 minutes to obtain a mixture;

[0054] S2. Add polycarboxylate superplasticizer SPT-160UX, hydroxyethyl methyl cellulose ether, sodium gluconate, polyether defoamer, ethylene-vinyl acetate copolymer latex powder, shrinkage reducer, and lithium sulfate to a mixer and stir for 3 minutes. Add the mixture and composite fiber and continue stirring for 3 minutes. Then add water and stir for 3 minutes.

[0055] Example 3

[0056] An antistatic, non-sparking self-leveling mortar material comprises the following raw materials: 25.5 kg of cementitious material, 36 kg of sand, 1200 g of Grade I fly ash, 700 g of lime powder, 1500 g of antistatic fiber with a diameter of 0.5 ± 0.1 mm, 20.5 kg of composite fiber, 250 g of polycarboxylate superplasticizer SPT-160UX, 120 g of hydroxypropyl methylcellulose ether, 300 g of sodium gluconate, 60 g of polyether defoamer, 180 g of ethylene-vinyl acetate copolymer latex powder, 130 g of shrinkage reducer, 170 g of lithium sulfate, and 15 kg of water.

[0057] The cementitious material consists of P·Ⅱ52.5R silicate cement, L·SAC 42.5 low-alkalinity aluminum sulfate cement, and anhydrite in a mass ratio of 3:12:2. The sand consists of coarse sand with a particle size of 0.3-0.6mm and fine sand with a particle size of 0.1-0.2mm in a mass ratio of 1.7:1.3.

[0058] The composite fiber is obtained by plasma treatment (using air as the working gas, with an air flow rate of 2.5 L / min and a discharge power of 230 W) for 7 min, followed by the addition of 18 kg of non-sparking filler and stirring for 8 min at a stirring speed of 250 r / min, and then ultrasonic treatment (with an ultrasonic frequency of 82 kHz) for 25 min.

[0059] The non-sparking filler is obtained by heating 10 kg of limestone powder to 92°C to remove moisture, adding 400 g of nano silica and 150 g of KH550 coupling agent, grinding at 1100 r / min for 18 min, cooling to room temperature, and passing through a 210 mesh sieve.

[0060] The antistatic fiber is prepared by the following steps: 250g of graphene, 120g of polypyrrole, and 180g of polyvinylpyrrolidone are added to 700g of water and stirred evenly to obtain pretreated graphene; 1800g of cellulose pulp is added to 3500g of 1-ethyl-3-methylimidazolium chloride ionic liquid and stirred evenly; the pretreated graphene is added to the mixture and stirred evenly; and the mixture is then melt-extruded using a twin-screw extruder.

[0061] The preparation method of the above-mentioned antistatic, non-sparking self-leveling mortar material includes the following steps:

[0062] S1. Add cementitious materials, sand, Class I fly ash, antistatic fiber, and lime powder to a mixer and stir for 4 minutes to obtain a mixture;

[0063] S2. Add polycarboxylate superplasticizer SPT-160UX, hydroxypropyl methylcellulose ether, sodium gluconate, polyether defoamer, ethylene-vinyl acetate copolymer latex powder, shrinkage reducer, and lithium sulfate to a mixer and stir for 1.5 min. Add the mixture and composite fiber and continue stirring for 2.5 min. Then add water and stir for 1.5 min.

[0064] Example 4

[0065] An antistatic, non-sparking self-leveling mortar material comprises the following raw materials: 22.5 kg of cementitious material, 24 kg of sand, 1800 g of Grade I fly ash, 300 g of lime powder, 2500 g of antistatic fiber with a diameter of 0.5 ± 0.1 mm, 13.5 kg of composite fiber, 150 g of polycarboxylate superplasticizer SPT-160UX, 180 g of hydroxyethyl methyl cellulose ether, 200 g of sodium gluconate, 80 g of polyether defoamer, 120 g of ethylene-vinyl acetate copolymer latex powder, 170 g of shrinkage reducer, 130 g of lithium sulfate, and 15 kg of water.

[0066] The cementitious material consists of P·Ⅱ52.5R silicate cement, L·SAC 42.5 low-alkalinity aluminum sulfate cement, and anhydrite in a mass ratio of 11:24:10. The sand consists of coarse sand with a particle size of 0.3-0.6mm and fine sand with a particle size of 0.1-0.2mm in a mass ratio of 1.2:1.8.

[0067] The composite fiber is obtained by plasma treatment (using air as the working gas, with an air flow rate of 1.5 L / min and a discharge power of 210 W) for 9 min, followed by the addition of 12 kg of non-sparking filler and stirring for 12 min at a stirring speed of 150 r / min, and then ultrasonic treatment (with an ultrasonic frequency of 88 kHz) for 15 min.

[0068] The non-sparking filler is obtained by heating 10 kg of limestone powder to 98°C to remove moisture, adding 200 g of nano silica and 150 g of KH550 coupling agent, grinding at 1300 r / min for 12 min, cooling to room temperature, and passing through a 230 mesh sieve.

[0069] The antistatic fiber is prepared by the following steps: 150g of graphene, 180g of polypyrrole, and 120g of polyvinylpyrrolidone are added to 900g of water and stirred evenly to obtain pretreated graphene; 1200g of cellulose pulp is added to 4500g of 1-ethyl-3-methylimidazolium bis(trifluoromethanesulfonyl)imine salt ionic liquid and stirred evenly; the pretreated graphene is added to the mixture and stirred evenly; and the mixture is then melt-extruded using a twin-screw extruder.

[0070] The preparation method of the above-mentioned antistatic, non-sparking self-leveling mortar material includes the following steps:

[0071] S1. Add cementitious materials, sand, Class I fly ash, antistatic fiber, and lime powder to a mixer and stir for 2 minutes to obtain a mixture.

[0072] S2. Add polycarboxylate superplasticizer SPT-160UX, hydroxyethyl methyl cellulose ether, sodium gluconate, polyether defoamer, ethylene-vinyl acetate copolymer latex powder, shrinkage reducer, and lithium sulfate to a mixer and stir for 2.5 minutes. Add the mixture and composite fiber and continue stirring for 1.5 minutes. Then add water and stir for 2.5 minutes.

[0073] Example 5

[0074] An antistatic, non-sparking self-leveling mortar material comprises the following raw materials: 24 kg of cementitious material, 30 kg of sand, 1500 g of Grade I fly ash, 500 g of lime powder, 2 kg of antistatic fiber with a diameter of 0.5 ± 0.1 mm, 17 kg of composite fiber, 200 g of polycarboxylate superplasticizer SPT-160UX, 100 g of hydroxyethyl methyl cellulose ether, 50 g of hydroxypropyl methyl cellulose ether, 250 g of sodium gluconate, 70 g of polyether defoamer, 150 g of ethylene-vinyl acetate copolymer latex powder, 150 g of shrinkage reducer, 150 g of lithium sulfate, and 15 kg of water.

[0075] The cementitious material is composed of P·Ⅱ52.5R silicate cement, L·SAC 42.5 low-alkalinity aluminum sulfate cement, and anhydrite in a mass ratio of 50:150:40. The sand is composed of coarse sand with a particle size of 0.3-0.6mm and fine sand with a particle size of 0.1-0.2mm in a mass ratio of 1:2.

[0076] The composite fiber is obtained by plasma treatment (using air as the working gas, with an air flow rate of 2L / min and a discharge power of 220W) for 8 minutes, followed by the addition of 15kg of non-sparking filler and stirring for 10 minutes at a stirring speed of 200r / min, and then ultrasonic treatment (with an ultrasonic frequency of 85kHz) for 20 minutes.

[0077] The non-sparking filler is made by heating 10 kg of limestone powder to 95°C to remove moisture, adding 300 g of nano silica and 150 g of KH550 coupling agent, grinding at 1200 r / min for 15 min, cooling to room temperature, and passing through a 220 mesh sieve.

[0078] The antistatic fiber is prepared by the following steps: 200g of graphene, 150g of polypyrrole, and 150g of polyvinylpyrrolidone are added to 800g of water and stirred evenly to obtain pretreated graphene; 1500g of cellulose pulp is added to 4000g of chlorinated 1-(2-hydroxyethyl)-3-methylimidazolium salt ionic liquid and stirred evenly; the pretreated graphene is added to the mixture and stirred evenly; and the mixture is then melt-extruded using a twin-screw extruder.

[0079] The preparation method of the above-mentioned antistatic, non-sparking self-leveling mortar material includes the following steps:

[0080] S1. Add cementitious materials, sand, Class I fly ash, antistatic fiber, and lime powder to a mixer and stir for 3 minutes to obtain a mixture;

[0081] S2. Add polycarboxylate superplasticizer SPT-160UX, hydroxyethyl methyl cellulose ether, hydroxypropyl methyl cellulose ether, sodium gluconate, polyether defoamer, ethylene-vinyl acetate copolymer latex powder, shrinkage reducer, and lithium sulfate to a mixer and stir for 2 minutes. Add the mixture and composite fiber and continue stirring for 2 minutes. Then add water and stir for 2 minutes.

[0082] Comparative Example 1

[0083] An antistatic, non-sparking self-leveling mortar material comprises the following raw materials: 24 kg of cementitious material, 30 kg of sand, 1500 g of Grade I fly ash, 500 g of lime powder, 2 kg of antistatic fiber with a diameter of 0.5 ± 0.1 mm, 17 kg of composite fiber, 200 g of polycarboxylate superplasticizer SPT-160UX, 100 g of hydroxyethyl methyl cellulose ether, 50 g of hydroxypropyl methyl cellulose ether, 250 g of sodium gluconate, 70 g of polyether defoamer, 150 g of ethylene-vinyl acetate copolymer latex powder, 150 g of shrinkage reducer, 150 g of lithium sulfate, and 15 kg of water.

[0084] The cementitious material is composed of P·Ⅱ52.5R silicate cement, L·SAC 42.5 low-alkalinity aluminum sulfate cement, and anhydrite in a mass ratio of 50:150:40. The sand is composed of coarse sand with a particle size of 0.3-0.6mm and fine sand with a particle size of 0.1-0.2mm in a mass ratio of 1:2.

[0085] The composite fiber is obtained by mixing 2 kg of basalt fiber with a diameter of 0.5±0.1 mm with 15 kg of non-sparking filler for 10 min at a stirring speed of 200 r / min, and then ultrasonically treating it (ultrasonic frequency of 85 kHz) for 20 min.

[0086] The non-sparking filler is made by heating 10 kg of limestone powder to 95°C to remove moisture, adding 300 g of nano silica and 150 g of KH550 coupling agent, grinding at 1200 r / min for 15 min, cooling to room temperature, and passing through a 220 mesh sieve.

[0087] The antistatic fiber is prepared by the following steps: 200g of graphene, 150g of polypyrrole, and 150g of polyvinylpyrrolidone are added to 800g of water and stirred evenly to obtain pretreated graphene; 1500g of cellulose pulp is added to 4000g of chlorinated 1-(2-hydroxyethyl)-3-methylimidazolium salt ionic liquid and stirred evenly; the pretreated graphene is added to the mixture and stirred evenly; and the mixture is then melt-extruded using a twin-screw extruder.

[0088] The preparation method of the above-mentioned antistatic, non-sparking self-leveling mortar material includes the following steps:

[0089] S1. Add cementitious materials, sand, Class I fly ash, antistatic fiber, and lime powder to a mixer and stir for 3 minutes to obtain a mixture;

[0090] S2. Add polycarboxylate superplasticizer SPT-160UX, hydroxyethyl methyl cellulose ether, hydroxypropyl methyl cellulose ether, sodium gluconate, polyether defoamer, ethylene-vinyl acetate copolymer latex powder, shrinkage reducer, and lithium sulfate to a mixer and stir for 2 minutes. Add the mixture and composite fiber and continue stirring for 2 minutes. Then add water and stir for 2 minutes.

[0091] Comparative Example 2

[0092] An antistatic, non-sparking self-leveling mortar material comprises the following raw materials: 24 kg of cementitious material, 30 kg of sand, 1500 g of Grade I fly ash, 500 g of lime powder, 2 kg of antistatic fiber with a diameter of 0.5 ± 0.1 mm, 17 kg of composite fiber, 200 g of polycarboxylate superplasticizer SPT-160UX, 100 g of hydroxyethyl methyl cellulose ether, 50 g of hydroxypropyl methyl cellulose ether, 250 g of sodium gluconate, 70 g of polyether defoamer, 150 g of ethylene-vinyl acetate copolymer latex powder, 150 g of shrinkage reducer, 150 g of lithium sulfate, and 15 kg of water.

[0093] The cementitious material is composed of P·Ⅱ52.5R silicate cement, L·SAC 42.5 low-alkalinity aluminum sulfate cement, and anhydrite in a mass ratio of 50:150:40. The sand is composed of coarse sand with a particle size of 0.3-0.6mm and fine sand with a particle size of 0.1-0.2mm in a mass ratio of 1:2.

[0094] The composite fiber is obtained by plasma treatment (using air as the working gas, with an air flow rate of 2L / min and a discharge power of 220W) for 8 minutes, followed by the addition of 14.354kg limestone powder, 430.6g nano silica, and 215.4g KH550 coupling agent for 10 minutes at a stirring speed of 200r / min, and then ultrasonic treatment (ultrasonic frequency of 85kHz) for 20 minutes.

[0095] The antistatic fiber is prepared by the following steps: 200g of graphene, 150g of polypyrrole, and 150g of polyvinylpyrrolidone are added to 800g of water and stirred evenly to obtain pretreated graphene; 1500g of cellulose pulp is added to 4000g of chlorinated 1-(2-hydroxyethyl)-3-methylimidazolium salt ionic liquid and stirred evenly; the pretreated graphene is added to the mixture and stirred evenly; and the mixture is then melt-extruded using a twin-screw extruder.

[0096] The preparation method of the above-mentioned antistatic, non-sparking self-leveling mortar material includes the following steps:

[0097] S1. Add cementitious materials, sand, Class I fly ash, antistatic fiber, and lime powder to a mixer and stir for 3 minutes to obtain a mixture;

[0098] S2. Add polycarboxylate superplasticizer SPT-160UX, hydroxyethyl methyl cellulose ether, hydroxypropyl methyl cellulose ether, sodium gluconate, polyether defoamer, ethylene-vinyl acetate copolymer latex powder, shrinkage reducer, and lithium sulfate to a mixer and stir for 2 minutes. Add the mixture and composite fiber and continue stirring for 2 minutes. Then add water and stir for 2 minutes.

[0099] Comparative Example 3

[0100] An antistatic, non-sparking self-leveling mortar material comprises the following raw materials: 24 kg of cementitious material, 30 kg of sand, 1500 g of Grade I fly ash, 500 g of lime powder, 2 kg of antistatic fiber with a diameter of 0.5 ± 0.1 mm, 17 kg of composite fiber, 200 g of polycarboxylate superplasticizer SPT-160UX, 100 g of hydroxyethyl methyl cellulose ether, 50 g of hydroxypropyl methyl cellulose ether, 250 g of sodium gluconate, 70 g of polyether defoamer, 150 g of ethylene-vinyl acetate copolymer latex powder, 150 g of shrinkage reducer, 150 g of lithium sulfate, and 15 kg of water.

[0101] The cementitious material is composed of P·Ⅱ52.5R silicate cement, L·SAC 42.5 low-alkalinity aluminum sulfate cement, and anhydrite in a mass ratio of 50:150:40. The sand is composed of coarse sand with a particle size of 0.3-0.6mm and fine sand with a particle size of 0.1-0.2mm in a mass ratio of 1:2.

[0102] The composite fiber is obtained by plasma treatment (using air as the working gas, with an air flow rate of 2L / min and a discharge power of 220W) for 8 minutes, followed by the addition of 15kg of non-sparking filler and stirring for 10 minutes at a stirring speed of 200r / min, and then ultrasonic treatment (with an ultrasonic frequency of 85kHz) for 20 minutes.

[0103] The non-sparking filler is made by heating 10 kg of limestone powder to 95°C to remove moisture, adding 300 g of nano silica and 150 g of KH550 coupling agent, grinding at 1200 r / min for 15 min, cooling to room temperature, and passing through a 220 mesh sieve.

[0104] The antistatic fiber is prepared by the following steps: 200g of graphene and 150g of polyvinylpyrrolidone are added to 800g of water and stirred evenly to obtain pretreated graphene; 1500g of cellulose pulp is added to 4000g of 1-(2-hydroxyethyl)-3-methylimidazolium chloride ionic liquid and stirred evenly; the pretreated graphene is added to it and stirred evenly; the mixture is then melt-extruded using a twin-screw extruder and mixed evenly with 150g of polypyrrole.

[0105] The preparation method of the above-mentioned antistatic, non-sparking self-leveling mortar material includes the following steps:

[0106] S1. Add cementitious materials, sand, Class I fly ash, antistatic fiber, and lime powder to a mixer and stir for 3 minutes to obtain a mixture;

[0107] S2. Add polycarboxylate superplasticizer SPT-160UX, hydroxyethyl methyl cellulose ether, hydroxypropyl methyl cellulose ether, sodium gluconate, polyether defoamer, ethylene-vinyl acetate copolymer latex powder, shrinkage reducer, and lithium sulfate to a mixer and stir for 2 minutes. Add the mixture and composite fiber and continue stirring for 2 minutes. Then add water and stir for 2 minutes.

[0108] The fluidity, compressive strength (24h and 28d), flexural strength (24h and 28d) and impact resistance of the self-leveling mortar materials obtained in Example 5 and Comparative Examples 1-3 were determined with reference to JC / T 985-2017 "Cement-based Self-leveling Mortar for Floors".

[0109] like Figure 1As shown, the self-leveling mortar material obtained in Example 5 has the highest fluidity, which is better than that of Comparative Examples 1-3 (P<0.05), confirming that the self-leveling mortar material obtained in this invention meets the requirements for self-leveling construction and does not require manual leveling.

[0110] like Figure 2 and Figure 3 As shown, the self-leveling mortar material obtained in Example 5 has the highest compressive strength and flexural strength, which are superior to those of Comparative Examples 1-3 (P<0.05).

[0111] During the impact resistance test, the self-leveling mortar materials obtained in Example 5 and Comparative Examples 2-3 did not show any cracking or detachment from the base plate.

[0112] The non-sparking and antistatic properties of the self-leveling mortar materials obtained in Example 5 and Comparative Examples 1-3 were tested in accordance with JC / T 2653-2022 "Non-sparking Mortar".

[0113] Among them, no sparks were observed in the self-leveling mortar materials obtained in Example 5, Comparative Example 1, and Comparative Example 3. Figure 4 As shown, the self-leveling mortar material obtained in Example 5 has the lowest surface resistance, indicating that the self-leveling mortar material obtained in this invention has the best antistatic properties.

[0114] The reasons for the above results are as follows: In the non-sparking filler used in this invention, the surface of limestone powder is coated with KH550 coupling agent and combined with nano-silica. The introduction of nano-silica enhances the toughness and deformability of the limestone powder, allowing it to absorb energy through plastic deformation upon impact, avoiding local energy accumulation and high-temperature ignition. Simultaneously, the KH550 coupling agent improves the interfacial bonding between the inorganic filler and the organic matrix, increasing the overall impact resistance. Furthermore, the basalt fiber, after low-temperature plasma treatment, not only significantly increases its specific surface area but also introduces active groups such as hydroxyl and carbonyl groups, significantly improving its bonding strength with the non-sparking filler. This forms a three-dimensional network in the mortar, effectively preventing static electricity buildup and enhancing the interfacial adhesion between the fiber and the matrix, greatly improving the impact resistance of the composite material. Additionally, in the antistatic fiber used in this invention, graphene and polypyrrole are combined. Graphene provides a continuous conductive path for rapid charge conduction, while polypyrrole enhances conductivity stability. This combination results in low fiber surface resistance and stable conductivity. Antistatic fibers, combined with composite fibers, form a fiber skeleton in the mortar, which significantly improves the stability of the material's antistatic properties.

[0115] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An antistatic non-pyrophoric self-leveling mortar material, characterized in that, The raw materials thereof include, by mass fraction: cementitious material 160-320 parts, sand 200-400 parts, fly ash 10-20 parts, lime powder 1-10 parts, antistatic fiber 10-30 parts, composite fiber 110-230 parts, polycarboxylate superplasticizer 1-3 parts, cellulose ether 1-2 parts, retarder 1-4 parts, defoaming agent 0.5-1 part, latex powder 1-2 parts, shrinkage-reducing agent 1-2 parts, early strength agent 1-2 parts, and water 120-180 parts; The composite fiber is obtained by plasma treatment of basalt fiber, then adding non-firing filler and stirring, and then ultrasonic treatment; the mass ratio of basalt fiber to non-firing filler is 1-3:10-20; The non-firing filler includes limestone powder, nano silicon dioxide, and KH550 coupling agent; the mass ratio of limestone powder, nano silicon dioxide, and KH550 coupling agent is 100:1-5:1-2; The antistatic fiber is prepared by the following steps: adding graphene, polypyrrole, and dispersant into water and stirring to obtain pretreated graphene; adding cellulose pulp into ionic liquid and stirring, adding pretreated graphene into the ionic liquid and stirring, and melt extruding.

2. The anti-static non-pyrophoric self-leveling mortar material of claim 1, wherein, The cementitious material includes ordinary portland cement, aluminum sulfate cement, and hard gypsum; the mass ratio of ordinary portland cement, aluminum sulfate cement, and hard gypsum is 40-60:100-200:20-60.

3. The anti-static, non-pyrophoric, self-leveling mortar material of claim 1, wherein, The sand includes coarse sand with a particle size of 0.3-0.6 mm and fine sand with a particle size of 0.1-0.2 mm; the mass ratio of coarse sand to fine sand is 1-2:1-2.

4. The anti-static, non-pyrophoric, self-leveling mortar material of claim 1, wherein, The plasma treatment time is 5-10 min, and the plasma treatment working gas is air; the air flow during the plasma treatment process is 0.3-3 L / min, and the discharge power is 200-250 W.

5. The anti-static, non-pyrophoric, self-leveling mortar material of claim 1, wherein, The ionic liquid is any one of 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl) imide salt ionic liquid, 1-butyl-3-methylimidazolium chloride salt ionic liquid, 1-allyl-3-methylimidazolium chloride salt ionic liquid, 1-(2-hydroxyethyl)-3-methylimidazolium chloride salt ionic liquid, and 1-ethyl-3-methylimidazolium chloride ionic liquid.

6. The anti-static, non-pyrophoric, self-leveling mortar material of claim 5, wherein, The mass ratio of graphene, polypyrrole, dispersant, cellulose pulp, and ionic liquid is 1-3:1-2:1-2:10-20:30-50.

7. The anti-static, non-pyrophoric, self-leveling mortar material of claim 5, wherein, The dispersant is polyvinylpyrrolidone.

8. The anti-static, non-pyrophoric, self-leveling mortar material of claim 1, wherein, The defoaming agent is polyether defoaming agent; the retarder is sodium gluconate; and the early strength agent is lithium sulfate.

9. The anti-static, non-pyrophoric, self-leveling mortar material of claim 1, wherein, The cellulose ether includes at least one of hydroxypropyl methyl cellulose ether and hydroxyethyl methyl cellulose ether; and the latex powder is ethylene-vinyl acetate copolymer powder.

10. A process for the preparation of an antistatic non-flammable self-leveling mortar material according to any one of claims 1 to 9, characterized in that, The method includes the following steps: S1, stirring the cementitious material, sand, fly ash, antistatic fiber, and lime powder for 1-5 min to obtain a mixture; S2, stirring the polycarboxylate superplasticizer, cellulose ether, retarder, defoaming agent, latex powder, shrinkage-reducing agent, and early strength agent for 1-3 min, adding the mixture and composite fiber and continuing to stir for 1-3 min, and then adding water and stirring for 1-3 min.

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