Lightweight thermal insulation mortar with sound insulation effect and preparation method thereof

Abstract

The invention belongs to the field of building materials, and particularly relates to lightweight thermal insulation mortar with a sound insulation effect and a preparation method thereof. The lightweight thermal insulation mortar with the sound insulation effect is prepared from 200 to 260 parts of a cementing material, 230 to 270 parts of natural sand, 0.4 to 0.6 part of a water-retention thickening agent, 4 to 6 parts of an adhesive, 0.4 to 0.6 part of an anti-cracking agent, 50 to 70 parts of a porous material, 20 to 40 parts of regenerated rubber powder and 20 to 40 parts of sepiolite fiber. The preparation method comprises the following steps: stirring and mixing all the raw materials, and stirring with water according to the weight ratio of 1: (0.35-0.45) until the mixture is uniform. The mortar has excellent sound insulation, heat preservation and mechanical properties, is simple to construct, and is suitable for indoor floor sound insulation layers.

Description

Technical Field

[0001] This invention belongs to the field of building materials, specifically relating to a lightweight thermal insulation mortar with sound insulation effect and its preparation method. Background Technology

[0002] In recent years, the market has placed higher demands on building energy conservation and noise control, especially the impact sound insulation performance of residential floors, which has become one of the core indicators for measuring the quality of living. Among the current mainstream floor sound insulation solutions, sound-insulating mortar is widely used due to its convenient construction and moderate cost, but existing products still have multiple technical bottlenecks.

[0003] Traditional sound-insulating mortars often rely on single porous materials (such as perlite and vermiculite) to improve sound insulation, which frequently leads to an imbalance between thermal insulation and mechanical properties. For example, simply increasing the perlite content can reduce the thermal conductivity, but it also reduces the compressive strength of the mortar, making it difficult to meet floor load requirements. Some products add asphalt and waste plastics to achieve better sound insulation, which not only poses a risk of releasing volatile harmful substances but also leads to cracking and delamination later due to poor material compatibility. In addition, existing formulas have low utilization rates of recycled resources, and there is little large-scale application of recycled rubber powder made from waste tires, which not only fails to meet the "dual carbon" target but also drives up raw material costs.

[0004] Meanwhile, construction-level issues are also prominent: fibrous sound insulation components (such as glass fiber and mineral fiber) are prone to agglomeration, requiring the addition of dispersants to ensure uniform performance; the mortar has poor water retention, and the surface is prone to rapid water loss during summer construction, forming shrinkage cracks; the bonding strength with the concrete substrate is generally low, and hollow areas are likely to occur after long-term use. These problems make it difficult for existing sound insulation mortars to simultaneously meet the comprehensive requirements of "high sound insulation, strong thermal insulation, excellent mechanical properties, high environmental protection, and easy construction," necessitating the development of new formulas and preparation processes to overcome these bottlenecks.

[0005] Therefore, based on this, the technical solution of the present invention is proposed. Summary of the Invention

[0006] To address the problems existing in the prior art, this invention provides a lightweight thermal insulation mortar with sound insulation effect, comprising the following raw materials in parts by weight: 200-260 parts of cementitious material, 230-270 parts of natural sand, 0.4-0.6 parts of water-retaining thickener, 4-6 parts of adhesive, 0.4-0.6 parts of crack-resistant agent, 50-70 parts of porous material, 20-40 parts of recycled rubber powder, and 20-40 parts of sepiolite fiber.

[0007] Preferably, the lightweight thermal insulation mortar with sound insulation effect comprises the following raw materials in parts by weight: 230 parts of cementitious material, 250 parts of natural sand, 0.5 parts of water-retaining thickener, 5 parts of adhesive, 0.5 parts of crack-resistant agent, 60 parts of porous material, 30 parts of recycled rubber powder and 30 parts of sepiolite fiber.

[0008] Preferably, the gel material is silicate cement (Jidong Cement Plant), with a specification of PO 42.5; The silicate cement has a 3-day compressive strength of 27.8 MPa and a 28-day compressive strength of 50.9 MPa.

[0009] Preferably, the natural sand comprises medium sand and fine sand; wherein: The particle size of the medium sand is 0.6-3mm; The particle size of the fine sand is <0.6mm; The weight ratio of medium sand to fine sand is 3:2.

[0010] Preferably, the water-retaining and thickening agent is hydroxypropyl methylcellulose ether (Beijing Kuaiyi Company), with a viscosity of 200,000-250,000 mPa•s and an ash content of 2-4%, used to improve the water retention rate and mixing viscosity of the product; And / or, the adhesive is latex powder (Beijing Kuaiyi Company), the ash content of the latex powder is 4-6%, which is used to improve the bonding strength and product durability; And / or, the crack-resistant agent is polypropylene fiber (Beijing Sanwei Company), with a specification of 3-6mm, used to improve the crack resistance of the product.

[0011] Preferably, the porous material is perlite (Hengxin Perlite Co., Ltd.), which has a rich pore structure and possesses sound absorption, heat insulation, and fire resistance properties; wherein: The perlite has a particle size of 1-3 mm and a bulk density of 60-70 kg / m³. 3 Its thermal conductivity is 0.048-0.050 W / (mK).

[0012] Preferably, the recycled rubber powder (derived from waste tires) has a particle size of 40-60 mesh, which has good damping performance; it is a hydrophobic material with the characteristics of acid and alkali resistance, good chemical stability, and non-degradation under natural conditions, and has been widely used in vibration reduction.

[0013] Preferably, the sepiolite fiber has a fiber length of 4-8 mm and a thermal conductivity of 0.038-0.046 W / (mK). It is a magnesium-rich silicate fiber mineral with the chemical formula MgO[SiO2]. 12 O 30 [(OH)4·12 H2O] has many advantages such as light weight, heat insulation, sound insulation, electrical insulation and good chemical stability.

[0014] Based on the same technical concept, another aspect of the present invention is to provide a method for preparing lightweight thermal insulation mortar with sound insulation effect, the preparation method comprising the following steps: (1) Mix all the raw materials together to obtain a mixture; (2) Mix the mixture with water until the system is homogeneous.

[0015] Preferably, in step (2), the weight ratio of the mixture to water is 1:0.35-0.45.

[0016] The beneficial effects of this invention are as follows: The lightweight thermal insulation mortar with sound insulation effect and its preparation method provided by this invention specifically solve the core pain points of existing sound insulation mortars, such as "difficulty in achieving both sound insulation and thermal insulation, insufficient mechanical strength, poor environmental performance, and easy problems during construction". Through component synergistic design and process optimization, it achieves a comprehensive improvement in sound insulation, thermal insulation, mechanical properties, environmental protection, and construction performance, and has significant practical value and industrialization prospects.

[0017] 1. Significant improvement in sound insulation performance: The innovative blend of recycled rubber powder and sepiolite fiber forms a dual sound insulation mechanism of "damping vibration reduction + pore sound absorption" - the high damping characteristics of recycled rubber powder can weaken the transmission of impact sound waves, and the layered pore structure of sepiolite fiber can absorb airborne sound, ultimately resulting in a significant improvement in noise reduction.

[0018] 2. Precise balance between thermal insulation and mechanical properties: Sepiolite fiber forms a three-dimensional skeleton in the mortar system. During the research and development process, it was found that it can increase the compressive strength by 16.2% (up to 4.59MPa) and the tensile bond strength by 33.3% (up to 0.24MPa), which solves the contradiction that "high content of porous materials leads to low strength". At the same time, perlite (thermal conductivity 0.048-0.050W / (mK)) and sepiolite fiber (thermal conductivity 0.038-0.046W / (mK)) work together to reduce the thermal conductivity of the system, ensuring that the thermal insulation performance meets the standards.

[0019] 3. Excellent in both environmental protection and economy: It uses recycled rubber powder (40-60 mesh) made from waste tires as raw material to realize the resource utilization of solid waste, reducing the cost of each ton of raw materials by 15%-20%; all components have no obvious volatile organic compounds, and sepiolite fiber, silicate cement and other materials are natural or green building materials, which meet the requirements of indoor environmental health and are compatible with green building evaluation standards.

[0020] 4. Significantly enhanced construction adaptability: By optimizing the pretreatment of raw materials (such as fiber pre-dispersion and sand drying) and the order of feeding, component agglomeration is avoided; hydroxypropyl methylcellulose ether (200,000-250,000 mPa•s) improves water retention, allowing construction at (23±2)℃ without additional moisturizing; the mortar consistency is stable at 50±5mm, with strong adhesion to the base layer, low shrinkage, and only 7 days of curing, improving construction efficiency by 20% compared to traditional products. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Figure 1 It is a soundproof enclosure test piece.

[0023] Figure 2 This is a schematic diagram of the sound insulation performance test points.

[0024] Figure 3 The graph shows the effect of different perlite to sepiolite fiber mass ratios on various properties of sound insulation mortar.

[0025] Figure 4 The graph shows the effect of different perlite to rubber powder mass ratios on various properties of sound insulation mortar.

[0026] Figure 5 These are actual photos showing the construction results. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be described in detail below. Obviously, the described embodiments are merely some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other implementation methods obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0028] Example 1 This embodiment provides a method for preparing and constructing a lightweight thermal insulation mortar with sound insulation effect, specifically including the following steps: (1) Raw material pretreatment and quality inspection (1-1) Take 230 kg of silicate cement (specification PO 42.5, 3d compressive strength 27.8 MPa, 28d compressive strength 50.9 MPa) and sieve it to remove lumpy particles; (1-2) Take 150 kg of medium sand (particle size 0.6-3 mm) and 100 kg of fine sand (particle size < 0.6 mm) and dry them for 2 hours until the moisture content is ≤ 5%; (1-3) Take 30 kg of recycled rubber powder (40-60 mesh) and sieve it to remove excess impurities; (1-4) Take 30 kg of sepiolite fiber (4-8 mm in length, thermal conductivity 0.038-0.046 W / (mK)) and put it into a high-speed disperser. Disperse it at 1000 r / min for 2 minutes.

[0029] The purpose is to: remove impurities from cement to ensure uniform mixing in the subsequent process; dry sand and gravel to avoid affecting the water-to-material ratio due to moisture content; remove impurities from recycled rubber powder to ensure purity; and pre-disperse sepiolite fibers to prevent agglomeration that could lead to uneven performance.

[0030] (2) Dry materials are added and mixed in batches. (2-1) Pour the pretreated silicate cement, medium sand and fine sand into a forced mixer and mix at low speed for 5 minutes to initially mix the coarse and fine aggregates with the cementitious materials; (2-2) Add 0.5 kg of hydroxypropyl methylcellulose ether (viscosity 200000-250000 mPa•s, ash content 2-4%), 5 kg of latex powder (ash content 4-6%), and 0.5 kg of polypropylene fiber (specification 3-6 mm). Stir at medium speed for 3 minutes to ensure uniform dispersion of the additives. (2-3) Finally, add 60 kg of perlite (particle size 1-3 mm, bulk density 60-70 kg / m³). 3 The pretreated recycled rubber powder with a thermal conductivity of 0.048-0.050 W / (mK) and sepiolite fiber were mixed at high speed for 2 minutes, with a total dry mixing time of 10 minutes, to obtain a uniform mixture.

[0031] The purpose is to: feed the materials in batches to avoid excessively high local concentrations of additives, match different rotation speeds to the dispersion requirements of different raw materials, and dry mix for 10 minutes to ensure that all components are mixed without dead corners, thus laying the foundation for stable performance in the future.

[0032] (3) Adding water and stirring and consistency testing (3-1) Calculate the amount of water to be added based on 40% of the weight of the mixture (i.e., the total weight of the mixture × 0.4), and divide the water into two parts (60% + 40%). (3-2) Add 60% water at the beginning, stirring at medium speed for 2 minutes while adding water to allow the water and dry materials to be initially mixed; (3-3) Add the remaining 40% of water and stir at medium speed for 3 minutes until the mortar is a uniform paste without lumps; (3-4) Use a consistency meter to test the consistency of the mortar and ensure that it is within the range of 50±5mm (if the consistency is too high, add 1%-2% water; if it is too low, add a small amount of dry mix).

[0033] The purpose is to: add water in batches to avoid local areas being too dry or too thin, mix for 5 minutes to ensure the system is uniform, and test the consistency to ensure that the mortar meets the requirements for paving fluidity, thus preventing difficulty in leveling during construction.

[0034] (4) Pretreatment of the construction base layer (4-1) Clean the concrete floor base, sweep away dust with a broom, wipe away oil stains with acetone, and remove loose aggregate with a chisel to ensure that the base is free of impurities; (4-2) Use a 2m straightedge to check the flatness of the base layer. If the error exceeds 2mm, sand it smooth. (4-3) Prepare cement slurry interface agent with a water-cement ratio of 0.5. Apply it evenly to the base surface with a brush, with a thickness of 0.5-1mm. Let it stand for 10 minutes until the interface agent is surface dry (not sticky to the touch).

[0035] The purpose is to ensure that the mortar and the substrate are in close contact after the base layer is cleaned and polished, and the interface agent can enhance the bonding strength and prevent problems such as hollowing and delamination in the later stage.

[0036] (5) Mortar spreading, vibration and troweling (5-1) Spread the mixed mortar evenly on the base layer. The initial spreading thickness is 5mm higher than the design thickness. Use an aluminum alloy scraper to initially smooth it along the baseline. (5-2) Vibrate the mortar in the same direction with a vibrating ruler, and control the moving speed at 0.5m / s to remove air bubbles inside the mortar; (5-3) After vibration, smooth the surface with a wooden trowel and then polish it with an iron trowel to ensure that the surface flatness error is ≤3mm. After polishing, mark the construction area with a marker pen (to avoid accidental stepping).

[0037] The purpose is to: allow for vibration shrinkage during paving, use a vibratory ruler to release air to prevent internal pores from affecting mechanical properties, use troweling to ensure surface flatness and density, and avoid construction interference in marked areas.

[0038] (6) Standard maintenance and finished product protection (6-1) Within 1 hour after construction, cover with a 0.08mm thick polyethylene film to keep it moist, and fix the edges of the film to the base layer with tape; (6-2) Control the ambient temperature at (23±2)℃ and the relative humidity at (50±5)% for 7 days; (6-3) During the maintenance period, check the integrity of the film every day. If there is any damage, repair it immediately with tape. Do not step on it or place heavy objects on it. (6-4) After curing, remove the film and use a rebound hammer to test the surface hardness of the mortar (rebound value ≥35). If it passes the test, proceed to the next process.

[0039] Its purpose is to: cover and retain moisture to prevent cracking caused by excessive evaporation of moisture, maintain standard environmental curing to ensure that the mortar is fully hydrated and hardened, test hardness to verify whether the mechanical properties meet the standards, and protect the finished product to avoid later damage.

[0040] Example 2 This embodiment provides a method for preparing and constructing a lightweight thermal insulation mortar with sound insulation effect, specifically including the following steps: (1) Raw material pretreatment and quality inspection (1-1) Take 200 kg of silicate cement (specification PO 42.5, 3d compressive strength 27.8 MPa, 28d compressive strength 50.9 MPa) and sieve it to remove lumpy particles; (1-2) Take 150 kg of medium sand (particle size 0.6-3 mm) and 100 kg of fine sand (particle size < 0.6 mm) and dry them for 3 hours until the moisture content is ≤ 4%; (1-3) Take 20 kg of recycled rubber powder (40-60 mesh) and sieve it to remove excess impurities; (1-4) Take 20kg of sepiolite fiber (4-8mm in length, thermal conductivity 0.038-0.046W / (mK)) and put it into a high-speed disperser. Disperse it at 1000r / min for 3 minutes.

[0041] The purpose is to: remove impurities from cement to ensure uniform mixing in the subsequent process; dry sand and gravel to avoid affecting the water-to-material ratio due to moisture content; remove impurities from recycled rubber powder to ensure purity; and pre-disperse sepiolite fibers to prevent agglomeration that could lead to uneven performance.

[0042] (2) Dry materials are added and mixed in batches. (2-1) Pour the pretreated silicate cement, medium sand and fine sand into a forced mixer and mix at low speed for 5 minutes to initially mix the coarse and fine aggregates with the cementitious materials; (2-2) Add 0.4 kg of hydroxypropyl methylcellulose ether (viscosity 200000-250000 mPa•s, ash content 2-4%), 4 kg of latex powder (ash content 4-6%), and 0.4 kg of polypropylene fiber (specification 3-6 mm). Stir at medium speed for 3 minutes to ensure uniform dispersion of the additives. (2-3) Finally, add 50 kg of perlite (particle size 1-3 mm, bulk density 60-70 kg / m³). 3 The pretreated recycled rubber powder with a thermal conductivity of 0.048-0.050 W / (mK) and sepiolite fiber were mixed at high speed for 2 minutes, with a total dry mixing time of 10 minutes, to obtain a uniform mixture.

[0043] The purpose is to: feed the materials in batches to avoid excessively high local concentrations of additives, match different rotation speeds to the dispersion requirements of different raw materials, and dry mix for 10 minutes to ensure that all components are mixed without dead corners, thus laying the foundation for stable performance in the future.

[0044] (3) Adding water and stirring and consistency testing (3-1) Calculate the amount of water to be added based on 35% of the weight of the mixture (i.e., the total weight of the mixture × 0.4), and divide the water into two parts (70% + 30%). (3-2) Add 70% water at the beginning, stirring at medium speed for 2 minutes while adding water to allow the water and dry materials to be initially mixed; (3-3) Add the remaining 30% of water and stir at medium speed for 3 minutes until the mortar is a uniform paste without lumps; (3-4) Use a consistency meter to test the consistency of the mortar and ensure that it is within the range of 50±5mm (if the consistency is too high, add 1%-2% water; if it is too low, add a small amount of dry mix).

[0045] The purpose is to: add water in batches to avoid local areas being too dry or too thin, mix for 5 minutes to ensure the system is uniform, and test the consistency to ensure that the mortar meets the requirements for paving fluidity, thus preventing difficulty in leveling during construction.

[0046] (4) Pretreatment of the construction base layer (4-1) Clean the concrete floor base, sweep away dust with a broom, wipe away oil stains with acetone, and remove loose aggregate with a chisel to ensure that the base is free of impurities; (4-2) Use a 2m straightedge to check the flatness of the base layer. If the error exceeds 2mm, sand it smooth. (4-3) Prepare cement slurry interface agent with a water-cement ratio of 0.5. Apply it evenly to the base surface with a brush, with a thickness of 0.5-1mm. Let it stand for 10 minutes until the interface agent is surface dry (not sticky to the touch).

[0047] The purpose is to ensure that the mortar and the substrate are in close contact after the base layer is cleaned and polished, and the interface agent can enhance the bonding strength and prevent problems such as hollowing and delamination in the later stage.

[0048] (5) Mortar spreading, vibration and troweling (5-1) Spread the mixed mortar evenly on the base layer. The initial spreading thickness is 5mm higher than the design thickness. Use an aluminum alloy scraper to initially smooth it along the baseline. (5-2) Vibrate the mortar in the same direction with a vibrating ruler, and control the moving speed at 0.5m / s to remove air bubbles inside the mortar; (5-3) After vibration, smooth the surface with a wooden trowel and then polish it with an iron trowel to ensure that the surface flatness error is ≤3mm. After polishing, mark the construction area with a marker pen (to avoid accidental stepping).

[0049] The purpose is to: allow for vibration shrinkage during paving, use a vibratory ruler to release air to prevent internal pores from affecting mechanical properties, use troweling to ensure surface flatness and density, and avoid construction interference in marked areas.

[0050] (6) Standard maintenance and finished product protection (6-1) Within 1 hour after construction, cover with a 0.08mm thick polyethylene film to keep it moist, and fix the edges of the film to the base layer with tape; (6-2) Control the ambient temperature at (23±2)℃ and the relative humidity at (50±5)% for 7 days; (6-3) During the maintenance period, check the integrity of the film every day. If there is any damage, repair it immediately with tape. Do not step on it or place heavy objects on it. (6-4) After curing, remove the film and use a rebound hammer to test the surface hardness of the mortar (rebound value ≥35). If it passes the test, proceed to the next process.

[0051] Its purpose is to: cover and retain moisture to prevent cracking caused by excessive evaporation of moisture, maintain standard environmental curing to ensure that the mortar is fully hydrated and hardened, test hardness to verify whether the mechanical properties meet the standards, and protect the finished product to avoid later damage.

[0052] Example 3 This embodiment provides a method for preparing and constructing a lightweight thermal insulation mortar with sound insulation effect, specifically including the following steps: (1) Raw material pretreatment and quality inspection (1-1) Take 260 kg of silicate cement (specification PO 42.5, 3d compressive strength 27.8 MPa, 28d compressive strength 50.9 MPa) and sieve it to remove lumpy particles; (1-2) Take 150 kg of medium sand (particle size 0.6-3 mm) and 100 kg of fine sand (particle size < 0.6 mm) and dry them for 3 hours until the moisture content is ≤ 5%; (1-3) Take 40 kg of recycled rubber powder (40-60 mesh) and sieve it to remove excess impurities; (1-4) Take 40kg of sepiolite fiber (4-8mm in length, thermal conductivity 0.038-0.046W / (mK)) and put it into a high-speed disperser. Disperse it at 1000r / min for 2 minutes.

[0053] The purpose is to: remove impurities from cement to ensure uniform mixing in the subsequent process; dry sand and gravel to avoid affecting the water-to-material ratio due to moisture content; remove impurities from recycled rubber powder to ensure purity; and pre-disperse sepiolite fibers to prevent agglomeration that could lead to uneven performance.

[0054] (2) Dry materials are added and mixed in batches. (2-1) Pour the pretreated silicate cement, medium sand and fine sand into a forced mixer and mix at low speed for 5 minutes to initially mix the coarse and fine aggregates with the cementitious materials; (2-2) Add 0.6 kg of hydroxypropyl methylcellulose ether (viscosity 200000-250000 mPa•s, ash content 2-4%), 6 kg of latex powder (ash content 4-6%), and 0.6 kg of polypropylene fiber (specification 3-6 mm). Stir at medium speed for 3 minutes to ensure uniform dispersion of the additives. (2-3) Finally, add 70 kg of perlite (particle size 1-3 mm, bulk density 60-70 kg / m³). 3The pretreated recycled rubber powder with a thermal conductivity of 0.048-0.050 W / (mK) and sepiolite fiber were mixed at high speed for 2 minutes, with a total dry mixing time of 10 minutes, to obtain a uniform mixture.

[0055] The purpose is to: feed the materials in batches to avoid excessively high local concentrations of additives, match different rotation speeds to the dispersion requirements of different raw materials, and dry mix for 10 minutes to ensure that all components are mixed without dead corners, thus laying the foundation for stable performance in the future.

[0056] (3) Adding water and stirring and consistency testing (3-1) Calculate the amount of water to be added based on 45% of the weight of the mixture (i.e., the total weight of the mixture × 0.4), and divide the water into two parts (65% + 35%). (3-2) Add 65% water at the beginning, stirring at medium speed for 2 minutes while adding water to allow the water and dry materials to be initially mixed; (3-3) Add the remaining 35% water and stir at medium speed for 3 minutes until the mortar is a uniform paste without lumps; (3-4) Use a consistency meter to test the consistency of the mortar and ensure that it is within the range of 50±5mm (if the consistency is too high, add 1%-2% water; if it is too low, add a small amount of dry mix).

[0057] The purpose is to: add water in batches to avoid local areas being too dry or too thin, mix for 5 minutes to ensure the system is uniform, and test the consistency to ensure that the mortar meets the requirements for paving fluidity, thus preventing difficulty in leveling during construction.

[0058] (4) Pretreatment of the construction base layer (4-1) Clean the concrete floor base, sweep away dust with a broom, wipe away oil stains with acetone, and remove loose aggregate with a chisel to ensure that the base is free of impurities; (4-2) Use a 2m straightedge to check the flatness of the base layer. If the error exceeds 2mm, sand it smooth. (4-3) Prepare cement slurry interface agent with a water-cement ratio of 0.5. Apply it evenly to the base surface with a brush, with a thickness of 0.5-1mm. Let it stand for 10 minutes until the interface agent is surface dry (not sticky to the touch).

[0059] The purpose is to ensure that the mortar and the substrate are in close contact after the base layer is cleaned and polished, and the interface agent can enhance the bonding strength and prevent problems such as hollowing and delamination in the later stage.

[0060] (5) Mortar spreading, vibration and troweling (5-1) Spread the mixed mortar evenly on the base layer. The initial spreading thickness is 5mm higher than the design thickness. Use an aluminum alloy scraper to initially smooth it along the baseline. (5-2) Vibrate the mortar in the same direction with a vibrating ruler, and control the moving speed at 0.5m / s to remove air bubbles inside the mortar; (5-3) After vibration, smooth the surface with a wooden trowel and then polish it with an iron trowel to ensure that the surface flatness error is ≤3mm. After polishing, mark the construction area with a marker pen (to avoid accidental stepping).

[0061] The purpose is to: allow for vibration shrinkage during paving, use a vibratory ruler to release air to prevent internal pores from affecting mechanical properties, use troweling to ensure surface flatness and density, and avoid construction interference in marked areas.

[0062] (6) Standard maintenance and finished product protection (6-1) Within 1 hour after construction, cover with a 0.08mm thick polyethylene film to keep it moist, and fix the edges of the film to the base layer with tape; (6-2) Control the ambient temperature at (23±2)℃ and the relative humidity at (50±5)% for 7 days; (6-3) During the maintenance period, check the integrity of the film every day. If there is any damage, repair it immediately with tape. Do not step on it or place heavy objects on it. (6-4) After curing, remove the film and use a rebound hammer to test the surface hardness of the mortar (rebound value ≥35). If it passes the test, proceed to the next process.

[0063] Its purpose is to: cover and retain moisture to prevent cracking caused by excessive evaporation of moisture, maintain standard environmental curing to ensure that the mortar is fully hydrated and hardened, test hardness to verify whether the mechanical properties meet the standards, and protect the finished product to avoid later damage.

[0064] R&D example Based on the inventor's previous research, the basic formula of lightweight aggregate thermal insulation mortar was first determined, as shown in Table 1.

[0065] Table 1. Basic Formula for Lightweight Aggregate Thermal Insulation Mortar

[0066] Note: The dosage is per cubic meter.

[0067] The dry density of the lightweight aggregate thermal insulation mortar for the ground was tested to be 758 kg / m³. 3 It has a compressive strength of 3.95 MPa and a thermal conductivity of 0.190 W / (mK).

[0068] Based on the formula in Table 1, tests were conducted on the sound insulation performance, tensile bond strength, and compressive strength of two sound insulation materials, sepiolite fiber and recycled rubber powder, with different masses added. The test design is shown in Table 2.

[0069] Table 2 Experimental Design of Sound Insulation Mortar

[0070] The relevant performance testing methods are as follows: (1) Sound insulation performance test method The sound insulation performance test was conducted by impact sound insulation test using a self-made small sound insulation box. The small sound insulation box was assembled from composite insulation board and adhesive mortar, with external dimensions of 1100mm in length, 900mm in width, and 700mm in height. It was hollow inside, with a wall and bottom thickness of 100mm each.

[0071] like Figure 1 As shown, the specimen specifications are all 1100mm×900mm×30mm. The S1-S14 formulas were molded into specimens according to the specimen specifications. After molding, they were cured at (23±2)℃ and (50±5)% relative humidity for 28 days, and then the sound insulation performance was tested.

[0072] Test diagram as follows Figure 2 As shown, an impact sound source is placed inside a soundproof enclosure, and a specimen sample covers the enclosure. A decibel meter is used to measure the decibel values ​​at various test points on the inner and outer surfaces of the specimen.

[0073] (2) Compressive strength test method Formulas S1-S14 were molded in molds with dimensions of 70.7mm×70.7mm×70.7mm. The amount of water added during molding met the standard consistency of (50±5)mm. The detailed molding method and compressive strength test were based on the standard GB / T20473-2021 "Building Thermal Insulation Mortar".

[0074] (3) Tensile bond strength test The specimens were molded according to the tensile bond strength test method in GB / T29756-2013 "Test Method for Physical Properties of Dry-Mixed Mortar". After curing under standard conditions for 28 days, the tensile bond strength between the specimens and the standard concrete slab was tested.

[0075] (4) Experimental results and analysis (4-1) Results of compressive strength test The compressive strength test results for each formulation are shown in Table 3.

[0076] Table 3 Compressive strength test results

[0077] As can be seen from the compressive strength test results in Table 3, the compressive strength gradually increases with the increase of sepiolite fiber content. When the sepiolite fiber content is 40 kg, the compressive strength reaches its peak, and the compressive strength can be increased by up to 16.2%. As the amount of recycled rubber powder particles added increases, the compressive strength decreases.

[0078] (4-2) Results of tensile bond strength test The tensile bond strength test results for each formulation are shown in Table 4.

[0079] Table 4 Results of tensile bond strength test

[0080] As can be seen from the tensile bond strength test results in Table 4, the tensile bond strength gradually increases with the increase of sepiolite fiber content. When the sepiolite fiber content is 40 kg, the tensile bond strength reaches its peak, and the tensile bond strength can be increased by up to 33.3%. As the rubber powder content continues to increase, the tensile bond strength continuously decreases.

[0081] (4-3) Results of sound insulation performance test The sound insulation test results for each formulation are shown in Table 5.

[0082] Table 5 Sound Insulation Test Results

[0083] As can be seen from the sound insulation performance test results in Table 5, the addition of sepiolite fiber and rubber powder particles can improve the sound insulation performance of mortar. Moreover, the noise reduction gradually increases with the increase of the addition amount. The noise reduction of sepiolite fiber reaches the maximum value of 24.9 dB, which can improve the original noise reduction by 34.6%. The noise reduction of rubber powder particles reaches the maximum value of 23.9 dB, which can improve the original noise reduction by 29.2%.

[0084] (5) Comprehensive performance analysis and mix proportion determination (5-1) The effect of sepiolite fiber on the comprehensive performance of sound insulation mortar: plotting curves of different perlite to sepiolite fiber mass ratios and various performance characteristics of sound insulation mortar, such as... Figure 3 As shown.

[0085] from Figure 3 As can be seen, when the mass ratio of perlite to sepiolite fiber is within the range of 6:3 and 6:4, all properties achieve good results. The reason for this is that sepiolite fiber, with its excellent porous and layered crystal structure, possesses good adsorption and dispersion properties. It can be randomly dispersed in the mortar structure, acting as a skeletal support, thereby improving compressive strength and bond strength. However, as the dosage gradually increases, this skeletal support effect reaches its limit. Furthermore, the formation of numerous tiny sealed pores by the sepiolite fiber within the insulation material further reduces the thermal conductivity.

[0086] (5-2) The effect of recycled rubber powder on the comprehensive performance of sound insulation mortar. Curves were plotted showing the relationship between different mass ratios of recycled rubber powder to sepiolite fiber and various properties of the sound insulation mortar, such as... Figure 4 As shown.

[0087] from Figure 4As can be seen, when the mass ratio of perlite to rubber powder is within the range of 6:3 and 6:4, the overall performance can achieve good indicators. The reason for this is that in the sound insulation mortar system, rubber particles, being flexible materials, are more easily suspended in the mortar, reducing the compressive strength and adhesive strength of the mortar system. However, due to the good damping properties of the surface rubber powder particles, noise is reduced through the damping effect. After reaching the internal pore structure of the perlite, the sound wave transmission is weakened a second time, thus achieving a good sound insulation effect for the mortar.

[0088] (5-3) Determination of actual production ratio Based on the comprehensive analysis results and production economics, the optimal raw material ratio for production was determined as shown in Table 6 without reducing the thermal insulation performance of the product.

[0089] Table 6. Production Formula for Thermal Insulation and Soundproofing Mortar

[0090] (5-4) Construction Application Prepare the thermal insulation and soundproof mortar according to the formula in Table 6, add an appropriate amount of water and stir, controlling the consistency to 50±5mm to ensure good fluidity, plasticity, and hardened properties. After testing, a water-to-material ratio of 0.4±0.05 was used for construction trials. The construction steps are as follows: Base cleaning (ensuring the base is clean and dry) — verifying control lines and measuring ground elevation — mortar patch layout and slope adjustment — interface treatment (applying cement slurry or rolling interface agent) — thermal insulation and soundproof mortar application (smoothing and polishing) — curing (film covering or spray curing, curing period not less than 7 days). After hardening, the thermal insulation and soundproof mortar bonded well to the base, and no cracking occurred. The construction effect diagram is shown below. Figure 5 As shown.

[0091] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A lightweight thermal insulation mortar with sound insulation effect, characterized in that, The raw materials include the following parts by weight: 200-260 parts of cementitious material, 230-270 parts of natural sand, 0.4-0.6 parts of water-retaining thickener, 4-6 parts of adhesive, 0.4-0.6 parts of crack-resistant agent, 50-70 parts of porous material, 20-40 parts of recycled rubber powder and 20-40 parts of sepiolite fiber.

2. The lightweight thermal insulation mortar with sound insulation effect according to claim 1, characterized in that, The raw materials include the following parts by weight: 230 parts of cementitious material, 250 parts of natural sand, 0.5 parts of water-retaining thickener, 5 parts of adhesive, 0.5 parts of crack-resistant agent, 60 parts of porous material, 30 parts of recycled rubber powder and 30 parts of sepiolite fiber.

3. The lightweight thermal insulation mortar with sound insulation effect according to claim 1, characterized in that, The gel material is silicate cement with a specification of PO 42.5; The silicate cement has a 3-day compressive strength of 27.8 MPa and a 28-day compressive strength of 50.9 MPa.

4. The lightweight thermal insulation mortar with sound insulation effect according to claim 1, characterized in that, The natural sand includes medium sand and fine sand; wherein: The particle size of the medium sand is 0.6-3mm; The particle size of the fine sand is <0.6mm; The weight ratio of medium sand to fine sand is 3:

2.

5. The lightweight thermal insulation mortar with sound insulation effect according to claim 1, characterized in that, The water-retaining and thickening agent is hydroxypropyl methylcellulose ether, with a viscosity of 200,000-250,000 mPa•s and an ash content of 2-4%; And / or, the adhesive is latex powder, and the ash content of the latex powder is 4-6%; And / or, the crack-resistant agent is polypropylene fiber with a specification of 3-6mm.

6. The lightweight thermal insulation mortar with sound insulation effect according to claim 1, characterized in that, The porous material is perlite; wherein: The perlite has a particle size of 1-3 mm and a bulk density of 60-70 kg / m³. 3 Its thermal conductivity is 0.048-0.050 W / (mK).

7. The lightweight thermal insulation mortar with sound insulation effect according to claim 1, characterized in that, The particle size of the recycled rubber powder is 40-60 mesh.

8. The lightweight thermal insulation mortar with sound insulation effect according to claim 1, characterized in that, The sepiolite fiber has a fiber length of 4-8 mm and a thermal conductivity of 0.038-0.046 W / (mK).

9. A method for preparing the lightweight thermal insulation mortar with sound insulation effect according to any one of claims 1-8, characterized in that, The preparation method includes the following steps: (1) Mix all the raw materials together to obtain a mixture; (2) Mix the mixture with water until the system is homogeneous.

10. The method for preparing the lightweight thermal insulation mortar with sound insulation effect according to claim 9, characterized in that, In step (2), the weight ratio of the mixture to water is 1:0.35-0.45.

Images