Rock wool-based thermal insulation wall material and preparation method thereof
By preparing rock wool-based lightweight aggregate A and combining it with composite fine aggregate, the shortcomings of existing building exterior wall insulation materials in terms of fire resistance, thermal insulation and mechanical properties are solved, achieving a balance between high efficiency, energy saving and safety. The material has stable thermal insulation performance in humid environments and has good fire resistance and mechanical properties.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- NANJING TONTECH ROCKWOOL CO LTD
- Filing Date
- 2026-01-26
- Publication Date
- 2026-05-01
AI Technical Summary
Existing building exterior wall insulation materials are difficult to balance good fire resistance, thermal insulation, mechanical properties and construction friendliness. Furthermore, inorganic materials such as rock wool boards have problems such as high water absorption, soft texture and health hazards during construction.
Using rock wool-based lightweight aggregate A as a base, an inorganic cross-linked structure is formed by combining nanocellulose and silica sol. Closed-cell vitrified microspheres and silica fume from composite fine aggregate are added to prepare a rock wool-based thermal insulation wall material with high strength and low thermal conductivity.
It achieves a balance between high efficiency and energy saving and intrinsic safety. The material has stable thermal insulation performance in humid environments, good fire resistance and mechanical properties, and reduces construction hazards and costs.
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Abstract
Description
Technical Field
[0001] This invention relates to the field of thermal insulation building material preparation technology, specifically to a rock wool-based thermal insulation wall material and its preparation method. Background Technology
[0002] Currently, the construction industry has stringent requirements for the thermal insulation and fire resistance performance of building exterior walls. With the escalating global energy crisis and rising building safety standards, exterior wall materials need to balance energy conservation and fire prevention; however, existing materials on the market often fall short in this regard, presenting numerous problems. Currently, commonly used exterior wall insulation materials are divided into two categories: One type is organic insulation boards, such as polystyrene boards and polyurethane boards, which have good thermal insulation performance, are lightweight, have low thermal conductivity, and a density of only 15-30 kg / m³. 3 Firstly, there are inorganic materials, such as rock wool boards and foamed cement boards, which can reduce the building load. However, they are essentially similar to plastics, with an oxygen index generally below 26%, making them highly flammable and posing significant safety hazards. Secondly, there are inorganic materials, such as rock wool boards and foamed cement boards, which have good fire resistance, achieving a Class A non-combustible combustion rating and preventing the spread of fire. However, they also have drawbacks. Ordinary rock wool boards are soft, with a compressive strength of only 4-8 kPa, and are highly absorbent. When soaked in rainwater, their insulation effect decreases, and their thermal conductivity increases. The fiber dust generated during construction harms the health of construction workers and pollutes the environment. For foamed cement boards, increasing the strength reduces the insulation performance, while focusing on insulation results in a fragile texture prone to cracking.
[0003] In response to the above problems, and especially in order to make high-value use of the large amount of sediment, waste cotton and cutting scraps generated during the production of rock wool, this invention provides a rock wool-based thermal insulation wall material and its preparation method. Summary of the Invention
[0004] Technical problems to be solved To address the shortcomings of existing materials, this invention provides a rock wool-based thermal insulation wall material and its preparation method, aiming to transform rock wool solid waste into high-performance lightweight aggregate, thereby preparing a new type of wall material with good thermal insulation, fire resistance, mechanical properties and construction friendliness.
[0005] Technical solution To achieve the above objectives, the present invention provides the following technical solution: A rock wool-based thermal insulation wall material comprises the following raw materials in parts by weight: 25-35 parts silicate cement, 35-45 parts rock wool-based lightweight aggregate A, 15-25 parts composite fine aggregate, water-reducing agent, viscosity modifier and mixing water; The amount of water-reducing agent used is 0.18%-0.25% of the mass of the gel material, the amount of viscosity modifier used is 0.09%-0.135% of the mass of the gel material, and the ratio of the mass of water used to the mass of the gel material is 0.50-0.55. The composite fine aggregate is composed of closed-cell vitrified microspheres, silica fume, and recycled micro powder; The mass of the gel material is the sum of the mass of silicate cement and the mass of silica fume in the composite fine aggregate.
[0006] Furthermore, the rock wool-based lightweight aggregate A is specifically prepared by the following steps: Nanocellulose suspension was added to a high-speed stirring shear mill, followed by rock wool sediment and stirring. Then, a nonionic dispersant was added, the speed was increased, and stirring continued. Next, the speed was reduced, and an inorganic binder was added. Subsequently, the pH of the system was adjusted, the temperature was increased, and stirring was performed. After maturation, a foaming agent was added, and the mixture was stirred before being fed into a kneader. Kneading parameters were set, and the moisture content of the material was controlled. The material clumps were removed, aged, fed into a granulator, granulated, and dried to obtain porous aggregate. The porous aggregate was then replaced in anhydrous ethanol, impregnated in a hydrophobic modified liquid, washed with n-hexane, and finally dried to constant weight to obtain rock wool-based lightweight aggregate A.
[0007] Furthermore, the rock wool-based lightweight aggregate A is specifically prepared by the following steps: Add 8-12 wt% nanocellulose suspension to a high-speed stirring shear press. Add rock wool sediment at 500-800 rpm and stir for 15-20 minutes. Add a nonionic dispersant and increase the speed to 1000-1500 rpm, stirring for 10-15 minutes. Reduce the speed to 300-500 rpm and add the inorganic binder, completing the addition within 10-15 minutes. Then adjust the pH of the system to 4-6 using 0.1 mol / L hydrochloric acid solution. Raise the system temperature to 40-50℃ while maintaining stirring, and allow it to mature for 2 days. After 0-30 minutes, add foaming agent and stir for 5-10 minutes. Then, feed the mixture into a kneader, set the jacket temperature to 25-35℃ and the vacuum degree to ≥-0.08MPa, and knead. During the process, take samples at regular intervals and use a rapid moisture analyzer to measure the moisture content of the material. Control the moisture content to 38%-42%. Remove the kneaded material from the kneader and place it in a sealed environment at room temperature for 1-2 hours. Then, feed the aged material into a granulator for granulation, set the output particle size to 5-12mm, and dry it at 40-60℃ for 1-2 hours to obtain porous aggregate. The porous aggregate is immersed in anhydrous ethanol for 2-3 replacements, each for 1-2 hours, and then immersed in a hydrophobic modification solution for 6-12 hours at 50-60℃. The aggregate is then washed with n-hexane 2-3 times for 0.5-1 hours each time, and then dried to constant weight under hot air at 60-80℃ to obtain rock wool-based lightweight aggregate A.
[0008] Furthermore, the inorganic binder is silica sol with a solid content of 30%.
[0009] In the above reaction process, high-shear stirring fully encapsulates and disperses the rock wool sediment, forming a uniform initial composite system that provides a nano-reinforcing skeleton and flame-retardant basis for the material. Subsequently, silica sol is added under acidic conditions and heated for maturation, promoting the formation of an inorganic cross-linked structure. A foaming agent is then added, and the system is kneaded. In the initial kneading stage, the foaming agent begins to react, generating microbubbles and adjusting the material's moisture content. Aging is then used to uniformly distribute moisture and stress. Extrusion granulation shapes the plastic agglomerates into regular wet granules. Pre-drying under mild conditions allows for slow evaporation of moisture, while the foaming agent continuously generates gas. The gas expands and forms a uniform microporous structure inside the granules, significantly reducing solvent consumption in subsequent hydrophobic modification processes. Hydrophobic modification is then achieved through ethanol replacement and silane impregnation.
[0010] During the hydrophobic modification process, a hydrophobic organosilicon layer is grafted onto the surface of the inner and outer pores of the aggregate to impart hydrophobic properties to the material, enabling the material to maintain stable thermal insulation performance in humid environments. Finally, it is dried to prepare rock wool-based lightweight aggregate A.
[0011] Furthermore, the nonionic dispersant is selected from at least one of polyethylene oxide (hereinafter referred to as PEO) and polyvinylpyrrolidone (hereinafter referred to as PVP).
[0012] Furthermore, the amount of the nonionic dispersant is 0.1%-0.2% of the total dry matter mass.
[0013] Furthermore, the mass ratio of rock wool sediment, nanocellulose suspension and inorganic binder is (4-6):(15-25):(10-15).
[0014] Furthermore, the foaming agent is aluminum powder paste and / or 30-50 wt% hydrogen peroxide solution.
[0015] Furthermore, the hydrophobic modified liquid is obtained by mixing trimethylchlorosilane and n-hexane in a volume ratio of 1:(5-8).
[0016] Furthermore, the composite fine aggregate is obtained by mixing closed-cell vitrified microspheres, silica fume and recycled micro powder in a mass ratio of (5-6):(3-4):(1-2).
[0017] Furthermore, the closed-cell vitrified microspheres are used after passing through a 40-60 mesh sieve.
[0018] Furthermore, the closed-cell vitrified microspheres have a particle size of 0.25-0.42 mm.
[0019] Furthermore, the silica fume particle size is less than 0.2 μm.
[0020] Furthermore, the recycled micro powder is waste fine powder generated during the production process of rock wool-based lightweight aggregate A.
[0021] In the above technical solution, the silica fume component in the composite fine aggregate can fill the rough pores of the rock wool-based lightweight aggregate A and the voids between the aggregate and the cement paste. On the one hand, this reduces the porosity of the interface zone; on the other hand, the highly active SiO2 of the silica fume can react with Ca(OH)2 produced by cement hydration to generate CSH gel with a low calcium-to-silicon ratio. This secondary hydration product can chemically bond the active SiO2 layer on the surface of aggregate A to the cement matrix, forming a dense and high-strength interface transition zone. The closed-cell vitrified microspheres have a smooth, closed-cell, and spherical shape, which can significantly improve the fluidity and encapsulation of the slurry. During pumping and casting, the closed-cell vitrified microspheres help the slurry flow more smoothly and tightly wrap around the rock wool-based lightweight aggregate A, ensuring that each coarse aggregate is fully wetted and bonded, avoiding slurry separation or uneven encapsulation caused by water absorption or irregular shape of aggregate A. Furthermore, closed-cell vitrified microspheres are themselves high-quality thermal insulation materials. Their extremely low thermal conductivity, combined with the ultra-low thermal conductivity of rock wool-based lightweight aggregate A, optimizes the overall thermal insulation performance of the concrete. Simultaneously, the composite fine aggregate also incorporates waste fine powder generated during the production of rock wool-based lightweight aggregate A, reducing costs. The chemical composition and surface characteristics of the micro-powder are completely consistent with aggregate A, further optimizing particle size distribution and acting as micro-nuclei in the paste to promote hydration and enhance the cohesion and homogeneity of the system.
[0022] Furthermore, the viscosity modifier is at least one of cellulose ether, biopolymer, and synthetic polymer.
[0023] Cellulose ethers include hydroxypropyl methylcellulose and hydroxyethyl cellulose. Biopolymers include lentinan, dimethyl cellulose, and xanthan gum. Synthetic polymers include polyacrylamide and polyvinyl alcohol.
[0024] In the above technical solution, the viscosity modifier can work synergistically with the microspheres in the composite fine aggregate to jointly construct a suitable yield stress and plastic viscosity, prevent the rock wool-based lightweight aggregate A from floating during vibration casting, and ensure the homogeneity of the structure.
[0025] Furthermore, the water-reducing agent is at least one of polycarboxylate-based water-reducing agents, naphthalene-based water-reducing agents, and aliphatic water-reducing agents.
[0026] Furthermore, the water-reducing agent is preferably a polycarboxylate-based water-reducing agent.
[0027] A method for preparing a rock wool-based thermal insulation wall material specifically includes the following steps: S1. Raw materials are taken according to dry material weight, and a forced mixer is used to feed and mix them in sequence to obtain a cohesive slurry; S2. After pumping the adhesive slurry into the mold coated with release agent, vibrate until the surface is covered with slurry and dense. Finally, steam curing is carried out to obtain rock wool-based thermal insulation wall material.
[0028] A method for preparing a rock wool-based thermal insulation wall material specifically includes the following steps: S1. Based on the dry weight, take silicate cement, rock wool-based lightweight aggregate A, composite fine aggregate, water-reducing agent, viscosity modifier, and mixing water. Use a forced mixer to add the following materials in the following order: first, add the composite fine aggregate, cement, and 2 / 3 of the water and mix for 30 seconds; then add the water-reducing agent and the remaining mixing water and mix for 60 seconds; then add the rock wool-based lightweight aggregate A and mix for 60-90 seconds; finally, add the dissolved viscosity modifier and mix for 60 seconds to obtain a cohesive slurry. S2. After pumping the adhesive slurry into the mold coated with the release agent, immediately vibrate it for 30-60 seconds with a 25-35Hz low-frequency adhesive vibrator until the surface is covered with slurry and dense; finally, steam curing is carried out to obtain a rock wool-based thermal insulation wall material.
[0029] Furthermore, the steam curing procedure is as follows: stand at room temperature for 2-3 hours, then raise the temperature to 65±5℃ at ≤15℃ / h and maintain the temperature and humidity for 6-8 hours, and finally lower the temperature to room temperature at ≤20℃ / h before demolding. After demolding, continue to maintain humidity for a total curing period of no less than 14 days.
[0030] Beneficial technical effects In this invention, the material system uses inorganic, non-combustible rock wool slag as the skeleton and silica sol as the bonding matrix, avoiding the use of organic bonding materials, thus giving the final wall material a naturally good fire-resistant effect. Regarding thermal insulation and energy saving, a porous structure is constructed within the rock wool-based lightweight aggregate A through a chemical foaming-kneading process, combined with closed-cell vitrified microspheres in the composite fine aggregate. This allows the wall material to achieve an extremely low thermal conductivity while maintaining structural integrity. Its thermal insulation performance is close to that of traditional organic insulation boards, but completely avoids their fatal flaw of flammability, achieving a balance between high efficiency and energy saving and inherent safety.
[0031] The introduction of nanocellulose in the material system enhances the flexibility and cohesion of the rock wool settling slag network. Silica sol provides stable inorganic cross-linking, while the silica fume in the composite fine aggregate tightly bridges the aggregate and cement matrix through the pozzolanic effect, forming a high-strength, dense interfacial transition zone. This allows the material to achieve high compressive strength at low density, meeting the basic mechanical performance requirements of self-insulating load-bearing walls. Detailed Implementation
[0032] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention are described clearly and completely. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.
[0033] The rock wool sludge used in the following examples and comparative examples was provided by Nanjing Tongtian Rock Wool Co., Ltd., and its specific composition is shown in Table 1 below: Table 1
[0034] The rock wool settling residue undergoes the following pretreatment before use: The collected rock wool sludge was placed on a vibrating screen and passed through a 20-mesh sieve at a vibration frequency of 50 Hz for 10 minutes. The sieved material was then added to a 5 wt% hydrochloric acid solution at a mass ratio of 1:5 and stirred in a water bath at 40°C for 30 minutes, with pH measured every 10 minutes. The reaction was stopped when the pH of the system reached 3-4. The rock wool sludge was washed until the pH of the washing liquid reached 6-7, and then air-dried at 60-80°C to constant weight.
[0035] Silicate cement: P.O42.5, Conch Cement.
[0036] The nanocellulose used has a length of 300-500 nanometers and a diameter of 10-20 nanometers.
[0037] The silica sol used is from BASF, model Ludox SM-30; the polycarboxylate superplasticizer is from BASF, model MasterGlenium 799.
[0038] Aluminum powder paste: Shengri Aopeng AP-02.
[0039] Trimethylchlorosilane and n-hexane were of analytical grade.
[0040] Examples 1-3 provide a method for preparing rock wool-based lightweight aggregate A and collect the waste fine powder generated during the production process.
[0041] Example 1 Rock wool-based lightweight aggregate A is prepared by the following steps: An 8wt% nanocellulose suspension was added to a high-speed mixing shear mill. Rock wool sediment was added at 500 rpm and stirred for 20 minutes. A nonionic dispersant was added and the speed was increased to 1000 rpm and stirred for 15 minutes. The speed was then reduced to 300 rpm and an inorganic binder was added, with the addition of the inorganic binder completed within 15 minutes. The pH of the system was then adjusted to 5 using a 0.1 mol / L hydrochloric acid solution. The system temperature was increased to 40°C and stirring was maintained. After maturing for 30 minutes, a foaming agent was added and stirred for 10 minutes. The mixture was then fed into a kneader, with the jacket temperature set at 35°C and the vacuum degree ≥-0.08 MPa. Kneading was performed, and samples were taken periodically during the process. The moisture content of the material was measured using a rapid moisture analyzer and controlled to be 40%. The kneaded material was removed from the kneader and aged in a sealed environment at room temperature for 2 hours. The aged material was then fed into a granulator for granulation, with the output particle size set to 5 mm. The material was dried at 40°C for 1 hour to obtain porous aggregate. The nonionic dispersant is selected from polyethylene oxide and is used at 0.1% of the total dry matter mass; the inorganic binder is silica sol; and the foaming agent is aluminum powder paste.
[0042] The porous aggregate was immersed in anhydrous ethanol for three replacements, each for 1 hour, and then immersed in a hydrophobic modification solution and kept at 50°C for 6 hours. The aggregate was then washed with n-hexane for 0.5 hours each time, and then dried to constant weight under hot air at 60°C to obtain rock wool-based lightweight aggregate A. The hydrophobic modification solution is obtained by mixing trimethylchlorosilane and n-hexane in a volume ratio of 1:5.
[0043] Example 2 Rock wool-based lightweight aggregate A is prepared by the following steps: A 10wt% nanocellulose suspension was added to a high-speed mixing shear mill. Rock wool sediment was added at 600 rpm and stirred for 20 minutes. A nonionic dispersant was added and the speed was increased to 1200 rpm and stirred for 15 minutes. The speed was then reduced to 400 rpm and an inorganic binder was added. The inorganic binder was added within 15 minutes. The pH of the system was then adjusted to 5 using 0.1 mol / L hydrochloric acid solution. The system temperature was increased to 40℃ and stirring was maintained. After maturation for 30 minutes, a foaming agent was added and stirred for 10 minutes. The mixture was then fed into a kneader. The jacket temperature was set to 35℃ and the vacuum degree to ≥-0.08 MPa for kneading. Samples were taken periodically during the process, and the moisture content of the material was measured using a rapid moisture analyzer. The moisture content was controlled to be 40%. The kneaded material was removed from the kneader and aged in a sealed environment at room temperature for 2 hours. The aged material was then fed into a granulator for granulation. The output particle size was set to 5 mm and dried at 40℃ for 2 hours to obtain porous aggregate. The nonionic dispersant is selected from polyethylene oxide and is used at 0.2% of the total dry matter mass; the inorganic binder is silica sol with a solid content of 30%; and the foaming agent is aluminum powder paste.
[0044] The porous aggregate was immersed in anhydrous ethanol for three replacements, each for 2 hours, and then immersed in a hydrophobic modification solution and kept at 50°C for 6 hours. The aggregate was then washed with n-hexane for 1 hour each time, and then dried to constant weight under hot air at 60°C to obtain rock wool-based lightweight aggregate A. The hydrophobic modification solution is obtained by mixing trimethylchlorosilane and n-hexane in a volume ratio of 1:6.
[0045] Example 3 Rock wool-based lightweight aggregate A is prepared by the following steps: A 12wt% nanocellulose suspension was added to a high-speed stirring shear press. Rock wool sediment was added at 600 rpm and stirred for 20 minutes. A nonionic dispersant was then added, and the stirring speed was increased to 1300 rpm and stirred for 15 minutes. The stirring speed was then reduced to 500 rpm, and the inorganic binder was added, with the addition of the inorganic binder completed within 15 minutes. Subsequently, the pH of the system was adjusted to 6 using 0.1 mol / L hydrochloric acid solution. The system temperature was increased to 50°C, and stirring was maintained. After maturing for 30 minutes, the following steps were taken: After adding the foaming agent and stirring for 10 minutes, the mixture is fed into a kneader. The jacket temperature is set to 35℃ and the vacuum degree is ≥-0.08MPa. During the kneading process, samples are taken at regular intervals, and the moisture content of the material is measured using a rapid moisture analyzer. The moisture content is controlled to be 38%-42%. The kneaded material is then removed from the kneader and aged in a sealed environment at room temperature for 2 hours. Subsequently, the aged material is fed into a granulator for granulation. The output particle size is set to 5mm, and the material is dried at 50℃ for 2 hours to obtain porous aggregate. The nonionic dispersant is selected from polyethylene oxide and is used at 0.2% of the total dry matter mass; the inorganic binder is silica sol with a solid content of 30%; and the foaming agent is aluminum powder paste.
[0046] The porous aggregate was immersed in anhydrous ethanol for three replacements, each for 2 hours, and then immersed in a hydrophobic modification solution and kept at 60°C for 10 hours. The aggregate was then washed with n-hexane three times for 1 hour each time, and then dried to constant weight under hot air at 80°C to obtain rock wool-based lightweight aggregate A. The hydrophobic modification solution is obtained by mixing trimethylchlorosilane and n-hexane in a volume ratio of 1:8.
[0047] Examples 4-6 provide a method for preparing rock wool-based thermal insulation wall materials.
[0048] Example 4 A rock wool-based thermal insulation wall material comprises the following raw materials in parts by weight: 25 parts silicate cement, 35 parts rock wool-based lightweight aggregate A prepared in Examples 1-3, 15 parts composite fine aggregate, water-reducing agent, viscosity modifier and mixing water; The amount of water-reducing agent used is 0.18% of the mass of the gel material, the amount of viscosity modifier used is 0.09% of the mass of the gel material, and the ratio of the mass of water used to the mass of the gel material is 0.50. The composite fine aggregate is obtained by mixing closed-cell vitrified microspheres, silica fume and recycled micro powder in a mass ratio of 5:3:1; the closed-cell vitrified microspheres have a particle size of 0.25 mm, the silica fume has a particle size of 0.1 μm, and the recycled micro powder is waste fine powder generated during the production process of rock wool-based lightweight aggregate A in Example 1, with a particle size of 0.1 μm.
[0049] The mass of the gel material is the sum of the mass of silicate cement and the mass of silica fume in the composite fine aggregate.
[0050] The preparation method of rock wool-based thermal insulation wall material as described above specifically includes the following steps: S1. Based on the dry weight, take silicate cement, rock wool-based lightweight aggregate A, composite fine aggregate, water-reducing agent, viscosity modifier, and mixing water. Use a forced mixer to add the following materials in the following order: first, add the composite fine aggregate, cement, and 2 / 3 of the water and mix for 30 seconds; then add the water-reducing agent and the remaining mixing water and mix for 60 seconds; then add the rock wool-based lightweight aggregate A and mix for 90 seconds; finally, add the dissolved viscosity modifier and mix for 60 seconds to obtain a cohesive slurry. S2. After pumping the adhesive slurry into the mold coated with the release agent, immediately vibrate it with a 35Hz low-frequency adhesive vibrator until the surface is covered with slurry and dense. Finally, steam curing is carried out. The steam curing procedure is as follows: stand at room temperature for 3 hours, then raise the temperature to 65℃ at 15℃ / h and keep it at a constant temperature and humidity for 8 hours. Finally, cool it down to room temperature at 20℃ / h and demold it. After demolding, continue to keep it moist for 14 days to obtain a rock wool-based thermal insulation wall material.
[0051] Example 5 A rock wool-based thermal insulation wall material comprises the following raw materials in parts by weight: 30 parts silicate cement, 40 parts rock wool-based lightweight aggregate A prepared in Example 2, 20 parts composite fine aggregate, water-reducing agent, viscosity modifier and mixing water; The amount of water-reducing agent used is 0.2% of the mass of the gel material, the amount of viscosity modifier used is 0.11% of the mass of the gel material, and the ratio of the mass of water used to the mass of the gel material is 0.55. The composite fine aggregate is obtained by mixing closed-cell vitrified microspheres, silica fume and recycled micro powder in a mass ratio of 6:3:1; the closed-cell vitrified microspheres have a particle size of 0.25 mm, the silica fume has a particle size of 0.1 μm, and the recycled micro powder is waste fine powder generated during the production process of rock wool-based lightweight aggregate A in Example 2, with a particle size of 0.1 μm.
[0052] The mass of the gel material is the sum of the mass of silicate cement and the mass of silica fume in the composite fine aggregate.
[0053] The preparation method of rock wool-based thermal insulation wall material as described above specifically includes the following steps: S1. Based on the dry weight, take silicate cement, rock wool-based lightweight aggregate A, composite fine aggregate, water-reducing agent, viscosity modifier, and mixing water. Use a forced mixer to add the following materials in the following order: first, add the composite fine aggregate, cement, and 2 / 3 of the water and mix for 30 seconds; then add the water-reducing agent and the remaining mixing water and mix for 60 seconds; then add the rock wool-based lightweight aggregate A and mix for 90 seconds; finally, add the dissolved viscosity modifier and mix for 60 seconds to obtain a cohesive slurry. S2. After pumping the adhesive slurry into the mold coated with the release agent, immediately vibrate it with a 35Hz low-frequency adhesive vibrator until the surface is covered with slurry and dense. Finally, steam curing is carried out. The steam curing procedure is as follows: stand at room temperature for 3 hours, then raise the temperature to 65℃ at 15℃ / h and keep it at a constant temperature and humidity for 8 hours. Finally, cool it down to room temperature at 20℃ / h and demold it. After demolding, continue to keep it moist for 14 days to obtain a rock wool-based thermal insulation wall material.
[0054] Example 6 A rock wool-based thermal insulation wall material comprises the following raw materials in parts by weight: 35 parts silicate cement, 45 parts rock wool-based lightweight aggregate A prepared in Example 3, 25 parts composite fine aggregate, water-reducing agent, viscosity modifier and mixing water; The amount of water-reducing agent used is 0.25% of the mass of the gel material, the amount of viscosity modifier used is 0.135% of the mass of the gel material, and the ratio of the mass of water used to the mass of the gel material is 0.55. The composite fine aggregate is obtained by mixing closed-cell vitrified microspheres, silica fume and recycled micro powder in a mass ratio of 6:4:2; the closed-cell vitrified microspheres have a particle size of 0.25 mm, the silica fume has a particle size of 0.1 μm, and the recycled micro powder is waste fine powder generated during the production process of rock wool-based lightweight aggregate A in Example 3, with a particle size of 0.1 μm.
[0055] The mass of the gel material is the sum of the mass of silicate cement and the mass of silica fume in the composite fine aggregate.
[0056] The preparation method of rock wool-based thermal insulation wall material as described above specifically includes the following steps: S1. Based on the dry weight, take silicate cement, rock wool-based lightweight aggregate A, composite fine aggregate, water-reducing agent, viscosity modifier, and mixing water. Use a forced mixer to add the following materials in the following order: first, add the composite fine aggregate, cement, and 2 / 3 of the water and mix for 30 seconds; then add the water-reducing agent and the remaining mixing water and mix for 60 seconds; then add the rock wool-based lightweight aggregate A and mix for 90 seconds; finally, add the dissolved viscosity modifier and mix for 60 seconds to obtain a cohesive slurry. S2. After pumping the adhesive slurry into the mold coated with the release agent, immediately vibrate it with a 35Hz low-frequency adhesive vibrator until the surface is covered with slurry and dense. Finally, steam curing is carried out. The steam curing procedure is as follows: stand at room temperature for 3 hours, then raise the temperature to 65℃ at 15℃ / h and keep it at a constant temperature and humidity for 8 hours. Finally, cool it down to room temperature at 20℃ / h and demold it. After demolding, continue to keep it moist for 14 days to obtain a rock wool-based thermal insulation wall material.
[0057] Comparative Example 1 The difference between this comparative example and Example 5 is that ordinary aggregate A is used instead of rock wool-based lightweight aggregate A, that is, aluminum powder foaming agent is not added. The remaining steps are the same as in Example 5. The specific preparation steps are as follows: A 10wt% nanocellulose suspension was added to a high-speed mixing shear mill. Rock wool sediment was added at 600 rpm and stirred for 20 minutes. A nonionic dispersant was added and the speed was increased to 1200 rpm and stirred for 15 minutes. The speed was then reduced to 400 rpm and an inorganic binder was added. The inorganic binder was added within 15 minutes. The pH of the system was then adjusted to 5 using 0.1 mol / L hydrochloric acid solution. The system temperature was increased to 40℃ and stirring was maintained. After maturation for 30 minutes, the mixture was fed into a kneader. The jacket temperature was set to 35℃ and the vacuum degree to ≥-0.08 MPa for kneading. Samples were taken periodically during the process, and the moisture content of the material was measured using a rapid moisture analyzer. The moisture content was controlled to be 40%. The kneaded material was removed from the kneader and aged in a sealed environment at room temperature for 2 hours. The aged material was then fed into a granulator for granulation. The output particle size was set to 5 mm and dried at 40℃ for 2 hours to obtain porous aggregate. The nonionic dispersant is selected from polyethylene oxide and is used at 0.2% of the total dry matter mass; the inorganic binder is silica sol with a solid content of 30%.
[0058] The porous aggregate was immersed in anhydrous ethanol for three replacements, each for 2 hours, and then immersed in a hydrophobic modification solution and kept at 50°C for 6 hours. The aggregate was then washed with n-hexane for 1 hour each time, and then dried to constant weight under hot air at 60°C to obtain ordinary aggregate A. The hydrophobic modification solution is obtained by mixing trimethylchlorosilane and n-hexane in a volume ratio of 1:6.
[0059] Comparative Example 2 The difference between this comparative example and Example 5 is that the composite fine aggregate is obtained by mixing closed-cell vitrified microspheres and fly ash in a mass ratio of 6:4; the fly ash particle size is 0.1 μm.
[0060] Comparative Example 3 The difference between this comparative example and Example 5 is that commercially available ceramsite with a particle size of 5-10 mm, a density grade of 700, a water absorption rate of >10%, and no hydrophobic modification was used to replace rock wool-based lightweight aggregate A.
[0061] The performance of the rock wool-based thermal insulation wall materials prepared in the examples and comparative examples is now being tested. The specific testing methods are as follows: Density test: The specimen was dried at (105±5)°C to constant weight, cooled to room temperature, weighed, and its volume was measured. The mass per unit volume was calculated.
[0062] Compressive strength test: A standard specimen of 100mm×100mm×100mm is uniformly loaded at a loading rate of 5kN / s on a universal testing machine until the specimen fails. The failure load is recorded and the compressive strength is calculated.
[0063] Thermal conductivity test: The prepared flat specimen is placed in a protective hot plate device. Under the set average temperature and heat flux conditions, the heat flux density passing through the specimen, the temperature difference between the two sides of the specimen, and the thickness are measured to calculate the thermal conductivity. The average test temperature is 25°C.
[0064] The specific test results are shown in Table 2 below: Table 2
[0065] As shown in Table 2, the sample in Example 5 exhibited the best performance. In Examples 5 and 6, the compressive strength increased compared to Example 5 with increasing cement content and material usage. The results from Comparative Example 1 show that the foaming process in this technical solution can effectively improve the material's lightweight nature and low thermal conductivity. The results from Comparative Example 2 show that the lack of pozzolanic activity and micro-filling effect from silica fume resulted in a decrease in compressive strength. This demonstrates that the composite fine aggregate in this invention can enhance interfacial bonding, improve mechanical properties, and increase volume stability. The results from Comparative Example 3 show that using ceramsite instead of rock wool-based lightweight aggregate A resulted in similar compressive strength, but increased density and thermal conductivity, leading to a decrease in performance as a lightweight and insulating material.
[0066] It should be noted that, in this document, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Unless otherwise specified, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.
[0067] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.
[0068] Those skilled in the art should understand that the above descriptions are merely several specific embodiments of the present invention, and not all embodiments.
Claims
1. A rock wool-based thermal insulation wall material, characterized in that, Includes the following quantities of raw materials: 25-35 parts silicate cement, 35-45 parts rock wool-based lightweight aggregate A, 15-25 parts composite fine aggregate, water-reducing agent, viscosity modifier and mixing water; The water-reducing agent is used at 0.18%-0.25% of the mass of the gel material, and the viscosity modifier is used at 0.09%-0.135% of the mass of the gel material. The ratio of mixing water to the mass of the gel material is 0.50-0.
55. The composite fine aggregate is composed of closed-cell vitrified microspheres, silica fume, and recycled micro powder. The mass of the gel material is the sum of the mass of silicate cement and the mass of silica fume in the composite fine aggregate.
2. The rock wool-based thermal insulation wall material according to claim 1, characterized in that, The rock wool-based lightweight aggregate A is prepared by the following steps: Nanocellulose suspension is added to a high-speed stirring shear mill, rock wool sediment is added and stirred; then a non-ionic dispersant is added and stirred; next, an inorganic binder is added, the pH of the system is adjusted to 4-6, the temperature is raised to 40-50℃ and stirred, after maturation, a foaming agent is added and stirred, and the mixture is fed into a kneader for kneading, controlling the moisture content of the material; the aggregate is removed, aged, granulated, and dried to obtain porous aggregate; the porous aggregate is replaced in anhydrous ethanol, impregnated in a hydrophobic modified liquid, soaked and washed with n-hexane, and finally dried to constant weight to obtain rock wool-based lightweight aggregate A.
3. The rock wool-based thermal insulation wall material according to claim 2, characterized in that, The nonionic dispersant is selected from at least one of polyethylene oxide and polyvinylpyrrolidone; the amount used is 0.1%-0.2% of the total dry matter mass.
4. The rock wool-based thermal insulation wall material according to claim 2, characterized in that, The mass ratio of rock wool sediment, nanocellulose suspension and inorganic binder is (4-6):(15-25):(10-15).
5. A rock wool-based thermal insulation wall material according to claim 2, characterized in that, The inorganic binder is silica sol.
6. The rock wool-based thermal insulation wall material according to claim 2, characterized in that, The foaming agent is aluminum powder paste and / or 30-50 wt% hydrogen peroxide solution.
7. A rock wool-based thermal insulation wall material according to claim 2, characterized in that, The hydrophobic modified liquid is obtained by mixing trimethylchlorosilane and n-hexane in a volume ratio of 1:(5-8).
8. A rock wool-based thermal insulation wall material according to claim 1, characterized in that, The composite fine aggregate is obtained by mixing closed-cell vitrified microspheres, silica fume and recycled micro powder in a mass ratio of (5-6):(3-4):(1-2).
9. A method for preparing a rock wool-based thermal insulation wall material according to any one of claims 1-8, characterized in that, Includes the following steps: S1. Raw materials are taken according to dry material weight, and a forced mixer is used to feed and mix them in sequence to obtain a cohesive slurry; S2. After pumping the adhesive slurry into the mold coated with release agent, vibrate until the surface is covered with slurry and dense. Finally, steam curing is carried out to obtain the rock wool-based thermal insulation wall material.
10. A method for preparing a rock wool-based thermal insulation wall material according to claim 9, characterized in that, The steam curing procedure is as follows: stand at room temperature for 2-3 hours, then raise the temperature to 65±5℃ at ≤15℃ / h and maintain the temperature and humidity for 6-8 hours, and finally lower the temperature to room temperature at ≤20℃ / h before demolding. After demolding, continue to maintain the humidity for a total curing period of no less than 14 days.