Polystyrene particle lightweight thermal insulation building material plate and preparation method thereof
By combining a three-layer polystyrene granular mortar structure with renewable dispersible latex powder, the performance imbalance of thermal insulation building materials is solved, achieving a balance between high thermal insulation and excellent mechanical properties, and producing a lightweight and stable thermal insulation building material board.
Patent Information
- Application Number
- CN202511550701.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-28
- Publication Date
- 2026-01-23
AI Technical Summary
Existing thermal insulation building materials cannot simultaneously achieve both low thermal conductivity and excellent mechanical properties. Traditional polystyrene boards have low compressive and flexural strength and are prone to cracking, while cement-based materials have high density and high thermal conductivity. The weak interfacial bonding between polystyrene particles and the cement matrix makes them prone to detachment, resulting in a decline in overall performance.
A lightweight thermal insulation building material board made of polystyrene particles is prepared by using a three-layer polystyrene particle mortar structure with different particle sizes, combined with renewable dispersible latex powder, and by vibration molding.
It achieves thermal insulation performance with a low thermal conductivity of 0.056 W/(mk), a 7-day flexural strength of 3.62 MPa and a compressive strength of 10.64 MPa, avoids particle shedding, improves overall stability, and meets the requirements of building energy conservation and structural safety.
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Abstract
Description
TECHNICAL FIELD
[0001] The present application belongs to the technical field of building materials, and particularly relates to a polystyrene particle lightweight thermal insulation building material plate and a preparation method thereof. BACKGROUND
[0002] With the continuous improvement of building energy-saving requirements, lightweight thermal insulation building materials are increasingly widely used in the field of construction. Ideal thermal insulation building materials need to meet the dual requirements of low thermal conductivity and excellent mechanical properties, but the existing technology often has performance imbalance problems. Traditional thermal insulation materials such as pure polystyrene board have outstanding thermal insulation properties, but have low compressive and bending strength and are prone to cracking and falling off. Ordinary cement-based building materials have good mechanical properties, but have poor thermal insulation effect due to high density, and the thermal conductivity is usually higher than 0.1 W / (m·K). In order to take advantage of both, the industry often adds polystyrene particles to cement mortar to prepare composite building materials, but the interfacial bonding force between the particles and the cement matrix is weak, and problems such as particle falling off and poor overall performance of the system often occur, resulting in a significant decrease in the mechanical properties of the material. In addition, increasing the amount of cement to improve the strength will sacrifice the lightweight and thermal insulation effect. Therefore, developing a thermal insulation building material plate that can retain the thermal insulation advantage of polystyrene particles and ensure the mechanical properties of cement-based materials has become a technical problem that needs to be solved in the current industry. SUMMARY
[0003] To solve the above technical problems, the technical scheme adopted by the present application is: a preparation method of a polystyrene particle lightweight thermal insulation building material plate, including the following processes: Step one, preparing lower layer mortar, middle layer mortar and upper layer mortar, adding a certain amount of cement, a certain amount of A-type polystyrene particles and a certain amount of standard sand in a certain amount of water, stirring to obtain the lower layer mortar; adding a certain amount of cement, a certain amount of B-type polystyrene particles and a certain amount of standard sand in a certain amount of water, stirring to obtain the middle layer mortar; adding a certain amount of cement, a certain amount of C-type polystyrene particles and a certain amount of standard sand in a certain amount of water, stirring to obtain the upper layer mortar; the particle size of the C-type polystyrene particles is 0.5-1 mm, the particle size of the A-type polystyrene particles is 2-4 mm, and the particle size of the B-type polystyrene particles is 3-5 mm; Step two, pouring the just stirred lower layer mortar into the mold, placing the mold on the vibration table, starting the vibration table to vibrate for a period of time; pouring the just stirred middle layer mortar into the mold, starting the vibration table to vibrate for a period of time; pouring the just stirred upper layer mortar into the mold, starting the vibration table to vibrate for a period of time; Step three, letting the mold stand still for 36-48 h, and then transferring it to a curing room for curing for 7 days; Step four, demolding to obtain the polystyrene particle lightweight thermal insulation building material plate.
[0004] As the preferred of the above technical solution, the weight ratio of cement and water in the lower layer mortar, the middle layer mortar and the upper layer mortar is 1:0.4-0.5, the weight ratio of cement and standard sand is 1:1-2, the A-type polystyrene particles in the lower layer mortar account for 0.5-1% of the total weight of the lower layer mortar, the C-type polystyrene particles in the upper layer mortar account for 2-3% of the total weight of the upper layer mortar, and the B-type polystyrene particles in the middle layer mortar account for 4-5% of the total weight of the middle layer mortar.
[0005] As the preferred of the above technical solution, the lower layer mortar, the middle layer mortar and the upper layer mortar contain a certain amount of renewable dispersible latex powder and a certain amount of water reducing agent, the weight ratio of cement and renewable dispersible latex powder is 1:0.01-0.03, and the weight ratio of cement and water reducing agent is 1:0.005-0.008.
[0006] As the preferred of the above technical solution, in the step two, after the lower layer mortar is vibrated in the mold, the vibration table is turned off after being vibrated for 10-20 seconds, and then the middle layer mortar is loaded; after the middle layer mortar is vibrated in the mold, the vibration table is turned off after being vibrated for 10-20 seconds, and then the upper layer mortar is loaded; after the upper layer mortar is vibrated in the mold, the vibration table is turned off after being vibrated for 10-20 seconds.
[0007] As the preferred of the above technical solution, the weight ratio of the lower layer mortar, the middle layer mortar and the upper layer mortar is 1:1.5-2.5:1.
[0008] As the preferred of the above technical solution, in the step one, cement is first added to the stirring pot, then A-type polystyrene particles, B-type polystyrene particles or C-type polystyrene particles are added, and then standard sand is added, and then low-speed stirring is carried out for a period of time, and then high-speed stirring is carried out for a period of time, and finally water is added and stirring is continued to obtain the lower layer mortar, the middle layer mortar or the upper layer mortar.
[0009] The polystyrene particle light weight thermal insulation building material plate of the application has the advantages that: the polystyrene particle light weight thermal insulation building material plate has excellent heat insulation and mechanical properties due to the three-layer polystyrene particle mortar composite structure and the addition of renewable dispersible latex powder; the average thermal conductivity is as low as 0.056 W / (mk), the heat insulation performance is better than that of single mortar and latex powder-free system; the 7-day bending and compressive strengths are 3.62 MPa and 10.64 MPa, which are close to those of cement-based materials without particles, and the strength reduction problem caused by the addition of particles is solved; meanwhile, the particles are prevented from falling off, the overall stability is improved, the balance between light weight and practicability is achieved, and the building energy saving and structural safety requirements are met. DETAILED DESCRIPTION
[0010] The technical solutions of the present application will be described clearly and completely below. Obviously, the described embodiments are part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the protection scope of the present application.
[0011] Embodiment 1 The preparation method of the polystyrene particle light weight thermal insulation building material board comprises the following processes: Step one, preparation of the lower layer mortar, the middle layer mortar and the upper layer mortar: first, 882 parts of cement (composite Portland cement P.S32.5 type) are added into a stirring pot, then 40.5 parts of A type polystyrene particles are added, followed by the addition of 1309.5 parts of standard sand (Chinese ISO standard sand produced by Xiamen Aiseo Company of China according to B / T17671-1999), 18 parts of renewable dispersible latex powder and 6.3 parts of water reducing agent. First, low-speed stirring is performed for 5 min, then high-speed stirring is performed for 10 min, and finally 405 parts of water are added and stirring is continued for 20 min to obtain the lower layer mortar. In the stirring pot, 1764 parts of cement are added, followed by the addition of 135 parts of B type polystyrene particles, 2565 parts of standard sand, 36 parts of renewable dispersible latex powder and 12.6 parts of water reducing agent. First, low-speed stirring is performed for 5 min, then high-speed stirring is performed for 10 min, and finally 810 parts of water are added and stirring is continued for 20 min to obtain the middle layer mortar. In the stirring pot, 882 parts of cement are added, followed by the addition of 40.5 parts of C type polystyrene particles, 1309.5 parts of standard sand, 18 parts of renewable dispersible latex powder and 6.3 parts of water reducing agent. First, low-speed stirring is performed for 5 min, then high-speed stirring is performed for 10 min, and finally 405 parts of water are added and stirring is continued for 20 min to obtain the upper layer mortar. The particle size of the C type polystyrene particles is 0.5-1 mm, the particle size of the A type polystyrene particles is 2-4 mm, and the particle size of the B type polystyrene particles is 3-5 mm. The A type polystyrene particles, the B type polystyrene particles and the C type polystyrene particles have the same structure and composition, except that the particle sizes are different. The polystyrene particles are closed-cell light particles made by foaming process, which are white and opaque spherical or ellipsoidal, have smooth surface but honeycomb closed-cell structure, have a porosity of more than 95%, form a dense air wrapping layer, and have excellent lightweight characteristics due to the loose and porous structure, have extremely low apparent density, and are only 1 / 50-1 / 30 of the natural sand.
[0012] Step two, pour the just mixed lower layer mortar into the mold, the mold is placed on the vibration table, the vibration table starts to vibrate, the lower layer mortar is vibrated in the mold, then the mold is vibrated for about 15s, and then the middle layer mortar is poured into the mold; the middle layer mortar is vibrated in the mold, then the mold is vibrated for about 15s, and then the upper layer mortar is poured into the mold; the upper layer mortar is vibrated in the mold, then the mold is vibrated for about 15s, and then the mold is stopped.
[0013] Step three, the mold is static for 40h, and then is transferred to the curing room for curing for 7 days.
[0014] Step four, demolding, to obtain the polystyrene particle light thermal insulation building material board (40x40x160mm).
[0015] Comparative example 1 The building material board made of only the middle layer mortar is prepared, including the following processes: Step one, preparation of the middle layer mortar: add 1764 parts of cement in the stirring pot, then add 135 parts of B type polystyrene particles, then add 2565 parts of standard sand, 36 parts of renewable dispersible latex powder, and 12.6 parts of water reducing agent. Stir at low speed for 5min, then stir at high speed for 10min, and finally add 810 parts of water and continue to stir for 20min. The middle layer mortar is obtained after stirring. Another portion of the middle layer mortar is prepared in the same way.
[0016] Step two, pour half of the just mixed middle layer mortar into the mold, the mold is placed on the vibration table, the vibration table starts to vibrate, the mortar is vibrated in the mold, then the mold is vibrated for about 15s, and then another portion of the middle layer mortar is poured into the mold; the mortar is vibrated in the mold, then the mold is vibrated for about 15s, and then the other half of the middle layer mortar is poured into the mold; the mortar is vibrated in the mold, then the mold is vibrated for about 15s, and then the mold is stopped.
[0017] Step three, the mold is static for 40h, and then is transferred to the curing room for curing for 7 days.
[0018] Step four, demolding, to obtain the building material board made of only the middle layer mortar (40x40x160mm). More particles can be observed on the surface of the building material board, and because of the high content of polystyrene particles, the particles are easy to fall off and the texture is obviously light.
[0019] Comparative example 2 The preparation method of the building material board without polystyrene particles includes the following processes: Step one, preparation of lower layer mortar, middle layer mortar and upper layer mortar: first, add 882 parts of cement into the stirring pot, then add 1350 parts of standard sand, 18 parts of renewable dispersible latex powder, 6.3 parts of water reducing agent. First low speed stirring 5 min, then high speed stirring 10 min, finally add 405 parts of water, continue stirring 20 min, get the lower layer mortar. The middle layer mortar and the upper layer mortar are prepared by the same process; Step two, pour the just stirred lower layer mortar into the mold, the mold is placed on the vibration table, the vibration table starts to vibrate, after the lower layer mortar is vibrated in the mold, turn off the vibration table after about 15 seconds, then pour the middle layer mortar; after the middle layer mortar is vibrated in the mold, turn off the vibration table after about 15 seconds, then pour the upper layer mortar; after the upper layer mortar is vibrated in the mold, turn off the vibration table after about 15 seconds; Step three, let the mold be still for 36-48h, then transfer to the curing room for 7 days; Step four, demolding, get the building material plate (40x40x160mm) without polystyrene particles.
[0020] Comparative example 3 The preparation method of the building material plate without renewable dispersible latex powder includes the following processes: Step one, preparation of lower layer mortar, middle layer mortar and upper layer mortar: first, add 882 parts of cement into the stirring pot, then add 1350 parts of standard sand, 18 parts of renewable dispersible latex powder, 6.3 parts of water reducing agent. First low speed stirring 5 min, then high speed stirring 10 min, finally add 405 parts of water, continue stirring 20 min, get the lower layer mortar. The middle layer mortar and the upper layer mortar are prepared by the same process; Step two, pour the just stirred lower layer mortar into the mold, the mold is placed on the vibration table, the vibration table starts to vibrate, after the lower layer mortar is vibrated in the mold, turn off the vibration table after about 15 seconds, then pour the middle layer mortar; after the middle layer mortar is vibrated in the mold, turn off the vibration table after about 15 seconds, then pour the upper layer mortar; after the upper layer mortar is vibrated in the mold, turn off the vibration table after about 15 seconds; Step three, the mold is static for 40h, then transfer to the curing room for curing for 7 days; Step four, demolding, to obtain polystyrene particle lightweight thermal insulation building material board (40x40x160mm) without renewable dispersible latex powder.
[0021] The building material board prepared in the above examples and comparative examples is subjected to performance test, and the test results are shown in the following table: From the above test results, it can be seen that the addition of a certain amount of polystyrene particles in the mortar system can effectively reduce the thermal conductivity of the building material board and improve its thermal insulation performance, but will affect the bending and compressive strength of the building material board. However, when a certain amount of renewable dispersible latex powder which is also a high molecular material is added, the building material board not only retains the thermal insulation performance, but also has the bending and compressive strength comparable to that of traditional cement mortar.
[0022] It is worth mentioning that the vibration table, stirring pot and other technical features involved in the present patent application should be regarded as prior art. The specific structure, working principle and possible control method and spatial arrangement method of these technical features can be selected by using conventional methods in the art, and should not be regarded as the invention point of the present patent. The present patent will not be further expanded and detailed.
[0023] The above detailed the preferred embodiments of the present application, it should be understood that those skilled in the art without inventive labor can make many modifications and changes according to the concept of the present application, therefore, any technical solution obtained by logical analysis, reasoning or limited experiment based on the existing technology according to the concept of the present application should be within the protection scope determined by the claims.
Claims
1. A method for preparing a polystyrene particle light weight thermal insulation building material board, characterized in that, The process comprises the following steps: Step 1: preparing the lower layer mortar, the middle layer mortar and the upper layer mortar, adding a certain amount of cement, a certain amount of A type polystyrene particles, a certain amount of standard sand into a certain amount of water, stirring to obtain the lower layer mortar; adding a certain amount of cement, a certain amount of B type polystyrene particles, a certain amount of standard sand into a certain amount of water, stirring to obtain the middle layer mortar; adding a certain amount of cement, a certain amount of C type polystyrene particles, a certain amount of standard sand into a certain amount of water, stirring to obtain the upper layer mortar; the particle size of the C type polystyrene particles is 0.5-1mm, the particle size of the A type polystyrene particles is 2-4mm, and the particle size of the B type polystyrene particles is 3-5mm; Step 2: pouring the just stirred lower layer mortar into the mold, placing the mold on the vibration table, starting the vibration table to vibrate for a period of time; pouring the just stirred middle layer mortar into the mold, starting the vibration table to vibrate for a period of time; pouring the just stirred upper layer mortar into the mold, starting the vibration table to vibrate for a period of time; Step 3: keeping the mold still for 36-48h, and then transferring it to a curing room for curing for 7 days; Step 4: demolding to obtain the polystyrene particle light weight thermal insulation building material plate.
2. The method for preparing the polystyrene particle lightweight thermal insulation building material board as described in claim 1, characterized in that, In the lower layer mortar, the middle layer mortar and the upper layer mortar, the weight ratio of cement and water is 1:0.4-0.5, the weight ratio of cement and standard sand is 1:1-2, the A type polystyrene particles in the lower layer mortar account for 0.5-1% of the total weight of the lower layer mortar, the C type polystyrene particles in the upper layer mortar account for 2-3% of the total weight of the upper layer mortar, and the B type polystyrene particles in the middle layer mortar account for 4-5% of the total weight of the middle layer mortar.
3. The method for preparing the lightweight thermal insulation building material board with polystyrene particles as described in claim 2, characterized in that, In the lower layer mortar, the middle layer mortar and the upper layer mortar, a certain amount of renewable dispersible latex powder and a certain amount of water reducing agent are contained, the weight ratio of cement and renewable dispersible latex powder is 1:0.01-0.03, and the weight ratio of cement and water reducing agent is 1:0.005-0.
008.
4. The method for preparing the lightweight thermal insulation building material board with polystyrene particles as described in claim 1, characterized in that, In step 2, the lower layer mortar is vibrated for 10-20s after being vibrated flat in the mold, and then the vibration table is turned off; then the middle layer mortar is poured in; the middle layer mortar is vibrated for 10-20s after being vibrated flat in the mold, and then the vibration table is turned off; then the upper layer mortar is poured in; the upper layer mortar is vibrated for 10-20s after being vibrated flat in the mold, and then the vibration table is turned off.
5. The method for preparing the lightweight thermal insulation building material board with polystyrene particles as described in claim 1, characterized in that, The weight ratio of the lower layer mortar, the middle layer mortar and the upper layer mortar is 1:1.5-2.5:
1.
6. The method for preparing the polystyrene particle lightweight thermal insulation building material board as described in claim 1, characterized in that, In step 1, the cement is first added into the stirring pot, then the A type polystyrene particles, the B type polystyrene particles or the C type polystyrene particles are added, and then the standard sand is added; low-speed stirring is first carried out for a period of time, high-speed stirring is then carried out for a period of time, and finally water is added for continuous stirring to obtain the lower layer mortar, the middle layer mortar or the upper layer mortar.