A green sound-insulating and heat-insulating mortar and its preparation method
Patent Information
- Application Number
- CN202610034260.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-12
- Publication Date
- 2026-05-26
Smart Images
Figure SMS_1
Abstract
Description
Technical Field
[0001] This invention relates to the field of building materials technology, specifically to a green sound-insulating and heat-insulating mortar and its preparation method. Background Technology
[0002] With increasing demands for building energy conservation and residential comfort, the market is placing higher requirements on the sound insulation and thermal insulation performance of walls and floors. Traditional plastering mortar, mainly composed of cement and sand, has high density and poor thermal and acoustic properties, making it difficult to meet these requirements. Lightweight sound-insulating and thermal-insulating mortar, as a functional plastering material, is experiencing growing market demand. In recent years, lightweight thermal-insulating mortar (often using vitrified microspheres and other aggregates) has been applied, but its sound insulation performance, especially its ability to isolate low-frequency impact sound, is generally insufficient, and it suffers from low strength and is prone to hollowing and cracking. Existing lightweight functional building materials face several common technical problems when being converted into plastering mortar: 1) Poor aggregate compatibility. To achieve lightweight and thermal insulation, low-density aggregates are often introduced, but their particle size or shape does not meet the gradation requirements of plastering mortar for fine aggregates, resulting in poor workability, easy segregation of the mortar, and a rough surface; 2) Prominent performance contradictions. Sound insulation requires dense materials or special damping structures, while thermal insulation requires porous and lightweight materials. Reconciling these contradictions in thin-layer mortar is quite difficult. 3) Insufficient early strength and toughness: the extensive use of lightweight or inert materials severely weakens the early strength and development speed of the cement matrix, affecting construction efficiency and crack resistance. Single fiber reinforcement is insufficient to meet the high requirements of plaster layers for resistance to plastic cracking and deformation adaptability. For example, placing the foaming process within the irreversible chemical process of cement setting leads to uncontrollable pore structure and large performance fluctuations.
[0003] Therefore, there is an urgent need to develop a new type of mortar system with an aggregate system specifically designed for plastering that can synergistically address multiple objectives such as lightweight, sound insulation, heat preservation, early strength and toughening, and has a stable and controllable production process. Summary of the Invention
[0004] The purpose of this invention is to provide a green sound-insulating and heat-insulating mortar and its preparation method, which is suitable for plastering construction of building interior walls, partition walls, and floor slab layers. It has the advantages of high-efficiency sound insulation, heat insulation, excellent crack resistance and high bonding strength, so as to solve the problems mentioned in the background art.
[0005] In a first aspect, the present invention provides a green sound-insulating and heat-insulating mortar, comprising the following raw materials by weight: 280-320 parts of sulfoaluminate cement; 40-60 parts of Grade II fly ash; 80-100 parts of epoxy resin modified EPS composite lightweight aggregate; 70-90 parts of silicon-aluminum based active activating admixture; 60-80 parts of closed-cell expanded vitrified microspheres; 15-20 parts of redispersible latex powder; Hydroxypropyl methylcellulose ether 1.8-2.2 parts; 2.5-3.5 parts of compound foaming agent; 0.8-1.2 parts of polypropylene fiber; Starch ether 0.5-0.7 parts; 0.7-0.9 parts of polycarboxylate superplasticizer; 150-180 parts water; 20-30 parts of hydrogen peroxide solution.
[0006] As a preferred embodiment of the present invention, the preparation method of the epoxy resin modified EPS composite lightweight aggregate is as follows: A1. Vibrate and screen the waste EPS foam to collect the primary EPS particles with a particle size of 0.6-1.2mm, and dry them at 40-55℃ for 2-3 hours. The raw material for the waste EPS foam is polystyrene foam boxes that have been mechanically crushed and ground at 5-15℃. A2. In the reactor, add bisphenol A type epoxy resin E-51 and acetone, and stir until completely dissolved; while continuously stirring, add ultrafine quartz powder, disperse evenly, add polyamide curing agent, and stir to form a coating slurry; The ultrafine quartz powder has a silica content of not less than 99% and a particle size of 300-500 mesh. The polyamide curing agent is 650 low molecular weight polyamide with an amine value of 200-240 mgKOH / g; The mass ratio of bisphenol A type epoxy resin E-51, acetone, ultrafine quartz powder and polyamide curing agent is 100:15:30:18. A3. Feed the primary EPS particles obtained in step A1 into a fluidized bed coating device. Set the fluidized bed inlet air temperature to 50-60℃ and adjust the air valve to make the fluidizing air volume reach 100-140m³ / h. 3 / h, set the atomization pressure to 0.2-0.4MPa; add the coating slurry obtained in step A2 to the storage tank, set the metering pump delivery rate to 17.5-23.5g / min, and continue spraying for 15-20min. After spraying, maintain the original operating parameters and let stand for 5min, turn off the spraying system and fluidizing fan, dry the material at 80℃ for 60min, cool it naturally to room temperature, and sieve it to obtain epoxy resin modified EPS composite lightweight aggregate with a particle size of 0.7-1.3mm; The mass ratio of the primary EPS particles to the coating slurry is 1:(0.3-0.4).
[0007] It should be noted that the epoxy resin modified EPS composite lightweight aggregate prepared in this invention uses waste polystyrene foam as raw material. In step A1, EPS primary particles of a specific particle size are obtained through sieving and drying, providing a basis for achieving uniform coating and also providing a resource utilization pathway for waste. In step A2, the coating slurry is prepared by dissolving bisphenol A type epoxy resin E-51 in acetone and diluting it to reduce viscosity and ensure the atomization and wetting effect of subsequent spraying. Ultrafine quartz powder is dispersed as a reinforcing filler and, together with the subsequently added polyamide curing agent, constitutes a crosslinkable composite system. Step A3 adopts a fluidized bed coating process, under controlled temperature and air... The process involves fluidizing the EPS particles while simultaneously spraying a coating slurry onto their surface in an atomized manner. This creates a slurry coating layer on the particle surface. During drying, the epoxy resin cross-links and cures, forming a composite shell with quartz powder that possesses a certain strength. The result is a core-shell lightweight aggregate with elastic EPS as the core and a relatively rigid epoxy resin-quartz powder composite as the shell. The core retains the inherent low density and elastic deformation capacity of EPS, while the shell enhances the particles' mechanical strength, wear resistance, and interfacial compatibility with inorganic cementitious materials, reducing breakage during transportation and mixing, and improving its hydrophilicity. When epoxy resin-modified EPS composite lightweight aggregate is applied to mortar, this composite aggregate, which balances strength and flexibility, effectively disperses and absorbs stress. The relatively high-hardness shell can bear some loads and improves adhesion to cement hydration products, reducing weak interfacial areas. The internal elastic core dissipates some energy through its viscoelastic deformation when the material is subjected to dynamic loads or sound waves. Meanwhile, the overall low thermal conductivity of the aggregate and the closed pores introduced into the mortar contribute to the thermal insulation performance. Through systematic surface engineering modification of waste EPS, the waste with poor mechanical properties and chemical stability is transformed into a high-performance composite lightweight aggregate, while simultaneously achieving material recycling and comprehensive performance improvement.
[0008] As a preferred embodiment of the present invention, the preparation method of the silicon-aluminum based active activating dopant is as follows: B1. Add silica powder and calcined kaolin into a planetary ball mill, add zirconium oxide grinding balls, and grind at a speed of 200-400 r / min for 40-50 min to obtain composite ultrafine powder; The specific surface area of the microsilica powder is not less than 15000 m². 2 / kg; The calcined kaolin is coal-series kaolin that has been calcined at 700-800℃ for 2-3 hours; The mass ratio of the microsilica powder to the calcined kaolin is 3:2; B2. Add the composite ultrafine powder obtained in step B1, anhydrous sodium sulfate powder, and triethanolamine together into a high-efficiency mixer, and mix in a closed container for 10-20 minutes to obtain a mixture. The mass ratio of the composite ultrafine powder, anhydrous sodium sulfate powder and triethanolamine is 195:4:1; B3. Place the mixture in a sealed container and let it stand at room temperature for 24-48 hours. Then dry and seal it for storage to obtain the silicon-aluminum based active activated admixture.
[0009] It should be noted that the preparation of the silicon-aluminum based active activating admixture is achieved through co-grinding of microsilica powder and calcined kaolin. This not only achieves uniform mixing of the materials but also increases the surface defects and reactive sites of the particles through mechanical activation, laying the foundation for subsequent chemical activation. The subsequently introduced anhydrous sodium sulfate and triethanolamine, in the alkaline environment provided by cement hydration, provide Na+... + With SO4 2- It can accelerate the dissolution of the active silica-alumina phase, promoting the early formation of more hydrated calcium silicate gel and ettringite; while triethanolamine also acts as an early hydration regulator, affecting the rate of cement mineral hydrolysis and providing lubrication and dispersion for powder particles, preventing agglomeration. The premixing process ensures that the activating components are distributed instantly and uniformly in the cementitious system, enabling the silica-alumina-based active activating admixture to replace part of the cement while improving the early strength and later density of the mortar by optimizing the formation of hydration products and microstructure.
[0010] As a preferred embodiment of the present invention, the preparation method of the composite foaming agent is as follows: C1. Weigh the porous silica-alumina carrier microspheres and place them in an impregnation tank; dissolve manganese nitrate and copper nitrate in deionized water to prepare a mixed solution 1 with a total metal ion concentration of 0.5 mol / L. Add the porous silica-alumina carrier microspheres in an equal volume impregnation manner while stirring. Let it stand at 25℃ for 12 h, dry at 110℃ for 6-8 h, place it in a muffle furnace and calcine it in air atmosphere at 330-380℃ for 3 h, and cool it to room temperature to obtain intermediate A. The mass ratio of manganese nitrate to copper nitrate is (265-275):(9-10); The porous silica-alumina carrier microspheres have a particle size of 50-150 μm and a specific surface area of not less than 350 m². 2 / g, pore size 2-50nm; C2. Place intermediate A obtained in step C1 into a second impregnation tank. Dissolve aluminum sulfate and polyvinyl alcohol in deionized water at 60°C to prepare a 20% mixed solution 2. Add the solution to intermediate A obtained in step C1 by impregnation with an equal volume while stirring. Let stand at 25°C for 6 hours and vacuum dry at 80°C for 10-12 hours to obtain intermediate B. The mass ratio of aluminum sulfate to polyvinyl alcohol is 5:1; C3. Add the intermediate B obtained in step C2 and the hydrophobic nano-silica to a low-speed mixer and mix at 15-20 r / min for 40-50 min at room temperature. After discharge, the composite foaming agent is obtained. The mass ratio of intermediate B to hydrophobic nano-silica is 50:1.
[0011] It should be noted that in the preparation process of the composite foaming agent, step C1 utilizes the high specific surface area and abundant pores of porous aluminosilicate microspheres as the structural matrix. Manganese and copper metal oxides are loaded in nanoscale form onto the inner surface of the pores through equal-volume impregnation and subsequent calcination, forming catalytic sites. Step C2 involves a second impregnation to load an aluminum sulfate and polyvinyl alcohol composite onto the modified support. After drying, the polyvinyl alcohol forms a polymer film, partially encapsulating and fixing the aluminum sulfate to prevent it from detaching or agglomerating. Step C3 introduces hydrophobic nano-silica to improve powder flowability and prevent pre-agglomeration during storage. The resulting composite foaming agent is a heterogeneous powder structure with porous aluminosilicate microspheres as the core, and its internal pores and surface sequentially loaded with catalytic oxides and an aluminum sulfate-polymer composite layer.
[0012] When the foaming agent and hydrogen peroxide solution are added together to the mortar, water molecules penetrate into the carrier pores, and hydrogen peroxide decomposes under the catalysis of manganese-copper oxide to produce oxygen, forming bubble nuclei; at the same time, the aluminum sulfate adhering to PVA dissolves, releasing Al. 3+ and SO4 2- Ions, in the alkaline environment of the cement paste, react with components such as calcium, silica, and aluminates from cement, fly ash, and silica-alumina-based admixtures, promoting the formation of early-strength hydration products such as ettringite within the paste (including the areas where bubble walls are forming). This process simultaneously achieves foaming and early matrix strength; the introduction of bubbles reduces density, while the timely release of sulfates helps strengthen the paste walls encapsulating the bubbles, thus macroscopically improving the early strength of the aerated mortar. This process, combined with the elastic behavior of epoxy resin-modified EPS composite lightweight aggregate, forms a multi-scale composite structure within the mortar, consisting of a reinforced paste matrix, elastic aggregate, and closed-cell bubbles. This achieves lightweighting while endowing the mortar with relatively excellent early strength development, impact toughness, and sound insulation capabilities after hardening.
[0013] A second aspect of the present invention provides a method for preparing green sound-insulating and heat-insulating mortar, comprising the following steps: S1. Add sulfoaluminate cement, Class II fly ash, silica-alumina-based active admixture, redispersible latex powder, hydroxypropyl methylcellulose ether, starch ether, and polycarboxylate superplasticizer into a zero-gravity mixer and mix at 25-35 r / min for 5-8 min to obtain premixed gelling dry powder. S2. Add epoxy resin modified EPS composite lightweight aggregate, closed-cell expanded vitrified microspheres and polypropylene fiber sequentially to the premixed gel dry powder obtained in step S1, and mix at a speed of 15-20 r / min for 4-5 min to obtain the finished dry-mixed mortar. S3. At the construction site, add water to the mortar mixer, add the finished dry mortar prepared in step S2 and mix for 1-2 minutes while stirring at a speed of 200-300 r / min. Then add the composite foaming agent and a 0.5-2% hydrogen peroxide solution and stir at a speed of 400-600 r / min for 10-60 seconds to obtain the final product.
[0014] Compared with the prior art, the present invention has the following beneficial effects: (1) This invention recycles and reuses waste EPS foam to prepare epoxy resin modified EPS composite lightweight aggregate with core-shell structure. It works in conjunction with closed-cell vitrified microspheres to form a systematic special lightweight aggregate, which improves the poor compatibility of traditional lightweight aggregate in plastering mortar. The hydrophilicity of its modified surface and its mechanical bonding ability with cement matrix are improved, reducing interface defects. At the same time, its internal elastic EPS core can provide a certain damping effect, so that the mortar can achieve a balance between lightweight and acceptable mechanical properties while obtaining good workability and surface smoothness. It has high early compressive strength, impact resistance and crack resistance.
[0015] (2) This invention introduces silicon-aluminum based active activating admixtures and composite foaming agents to synergistically regulate the microstructure of mortar through chemical activation and physical pore formation. The silicon-aluminum based active activating admixtures optimize the hydration process and improve the density of the matrix; while the composite foaming agent achieves a more uniform foaming process that matches the cement setting process, thereby introducing a relatively uniformly distributed closed-cell structure in the slurry, constructing multiple dissipation paths for sound wave propagation and reducing heat conduction. Thus, the mortar can achieve good sound insulation and heat preservation effects simultaneously with a thin plaster layer thickness, alleviating the contradiction between functional requirements.
[0016] (3) The preparation method of the present invention separates the pretreatment of functional components from the on-site construction process, which helps to ensure the stability of the quality of functional components, simplify the on-site construction process, and improve the uniformity of the final product performance and the reliability of the construction quality. Detailed Implementation
[0017] The technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present invention, and 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.
[0018] Preparation Example 1 The preparation method of epoxy resin modified EPS composite lightweight aggregate is as follows: A1. Waste EPS foam is obtained by mechanically crushing and grinding at 10℃, vibrating and screening to collect particles with an average particle size of 0.9mm, and drying at 50℃ for 2h to obtain primary EPS particles. A2. In the reactor, add 100g of bisphenol A type epoxy resin E-51 and 15g of acetone, and stir until completely dissolved; while stirring continuously, add 30g of ultrafine quartz powder, disperse evenly, add 18g of polyamide curing agent, and stir to form a coating slurry; The ultrafine quartz powder has a silica content of not less than 99% and an average particle size of 400 mesh. The polyamide curing agent is 650 low molecular weight polyamide with an amine value of 200-240 mgKOH / g; A3. Add 300g of the EPS primary particles obtained in step A1 into a fluidized bed coating device. Set the fluidized bed inlet air temperature to 55℃ and adjust the air valve to make the fluidizing air volume reach 120m³ / h. 3 / h, set the atomization pressure to 0.3MPa; add 105g of the coating slurry obtained in step A2 to the storage tank, set the metering pump delivery rate to 20g / min, and continue spraying for 18min. After spraying, maintain the original operating parameters and let stand for 5min. Turn off the spraying system and fluidizing fan, dry the material at 80℃ for 60min, cool it naturally to room temperature, and sieve it to obtain epoxy resin modified EPS composite lightweight aggregate with an average particle size of 1mm. Preparation Example 2 The preparation method of silicon-aluminum based active activating dopants is as follows: B1. Add 120g of silica powder and 80g of calcined kaolin to a planetary ball mill, add zirconium oxide grinding balls, and grind at 300r / min for 45min to obtain composite ultrafine powder. The calcined kaolin is coal-series kaolin that has been calcined at 750℃ for 2 hours; B2. Add 195g of the composite ultrafine powder obtained in step B1, 4g of anhydrous sodium sulfate powder and 1g of triethanolamine into a high-efficiency mixer, and mix in a closed container for 15 minutes to obtain a mixture. B3. Place the mixture in a sealed container, let it stand at room temperature for 36 hours, dry and seal it for storage to obtain the silicon-aluminum based active activated admixture.
[0019] Preparation Example 3 The preparation method of the composite foaming agent is as follows: C1. Weigh 100g of porous silica-alumina carrier microspheres and place them in an impregnation tank; dissolve 7.53g of manganese nitrate and 2.42g of copper nitrate in 80mL of deionized water to prepare a mixed solution 1 with a total metal ion concentration of 0.5mol / L. Add 100g of porous silica-alumina carrier microspheres under stirring, let stand at 25℃ for 12h, dry at 110℃ for 8h, place in a muffle furnace and calcine at 350℃ in air atmosphere for 3h, cool to room temperature to obtain intermediate A; C2. Place 100g of intermediate A obtained in step C1 into a second impregnation tank. Dissolve 13.33g of aluminum sulfate and 2.67g of polyvinyl alcohol in 80mL of deionized water at 60℃ to prepare a mixed solution 2 with a concentration of 20%. Add the mixed solution 2 to 100g of intermediate A obtained in step C1 while stirring. Let it stand at 25℃ for 6h and then vacuum dry at 80℃ for 12h to obtain intermediate B. C3. Add the intermediate B obtained in step C2 and the hydrophobic nano-silica to a low-speed mixer and mix at 20 r / min for 45 min at room temperature. After discharge, the composite foaming agent is obtained. The mass ratio of intermediate B to hydrophobic nano-silica is 50:1.
[0020] Example 1
[0021] A method for preparing a green sound-insulating and heat-insulating mortar includes the following steps: S1. By weight, 300 parts of sulfoaluminate cement, 50 parts of Class II fly ash, 80 parts of silica-alumina-based active activating admixture, 18 parts of redispersible latex powder, 2 parts of hydroxypropyl methylcellulose ether, 0.6 parts of starch ether, and 0.8 parts of polycarboxylate superplasticizer are put into a gravity-free mixer and mixed at 30 r / min for 6 min to obtain premixed gelling dry powder. S2. Add 90 parts of epoxy resin modified EPS composite lightweight aggregate, 70 parts of closed-cell expanded vitrified microspheres and 1 part of polypropylene fiber to the premixed gel dry powder obtained in step S1, and mix at 15 r / min for 4 min to obtain the finished dry-mixed mortar. S3. At the construction site, add 165 parts of water to the mortar mixer, add the finished dry mortar prepared in step S2 and stir for 2 minutes while stirring at 250 r / min. Add 3 parts of composite foaming agent and 25 parts of 1% hydrogen peroxide solution and stir at 500 r / min for 30 seconds to obtain the final product.
[0022] In this embodiment, some of the raw materials used are the same as those obtained in Preparation Examples 1-3, and the other examples are the same.
[0023] Example 2
[0024] A method for preparing a green sound-insulating and heat-insulating mortar includes the following steps: S1. By weight, 280 parts of sulfoaluminate cement, 40 parts of Class II fly ash, 70 parts of silica-alumina-based active activating admixture, 15 parts of redispersible latex powder, 1.8 parts of hydroxypropyl methylcellulose ether, 0.5 parts of starch ether, and 0.7 parts of polycarboxylate superplasticizer are put into a gravity-free mixer and mixed at 30 r / min for 6 min to obtain premixed gelling dry powder. S2. Add 80 parts of epoxy resin modified EPS composite lightweight aggregate, 60 parts of closed-cell expanded vitrified microspheres and 0.8 parts of polypropylene fiber to the premixed gel dry powder obtained in step S1, and mix at 15 r / min for 4 min to obtain the finished dry-mixed mortar. S3. At the construction site, add 150 parts of water to the mortar mixer, add the finished dry mortar prepared in step S2 and stir for 2 minutes while stirring at 250 r / min. Add 2.5 parts of composite foaming agent and 20 parts of 1% hydrogen peroxide solution and stir at 500 r / min for 30 seconds to obtain the final product.
[0025] Example 3
[0026] A method for preparing a green sound-insulating and heat-insulating mortar includes the following steps: S1. By weight, 320 parts of sulfoaluminate cement, 60 parts of Class II fly ash, 90 parts of silica-alumina-based active activating admixture, 20 parts of redispersible latex powder, 2.2 parts of hydroxypropyl methylcellulose ether, 0.7 parts of starch ether, and 0.9 parts of polycarboxylate superplasticizer are put into a gravity-free mixer and mixed at 30 r / min for 6 min to obtain premixed gelling dry powder. S2. Add 100 parts of epoxy resin modified EPS composite lightweight aggregate, 80 parts of closed-cell expanded vitrified microspheres and 1.2 parts of polypropylene fiber to the premixed gel dry powder obtained in step S1, and mix at 15 r / min for 4 min to obtain the finished dry-mixed mortar. S3. At the construction site, add 180 parts of water to the mortar mixer, add the finished dry mortar prepared in step S2 and stir for 2 minutes while stirring at 250 r / min. Add 3.5 parts of composite foaming agent and 30 parts of 1% hydrogen peroxide solution and stir at 500 r / min for 30 seconds to obtain the final product.
[0027] Comparative Example 1 The difference between this comparative example and Example 1 is that the epoxy resin modified EPS composite lightweight aggregate prepared in Example 1 was not added; instead, an equal part by weight of primary EPS particles was added.
[0028] Comparative Example 2 The difference between this comparative example and Example 1 is that the silicon-aluminum based active activating dopant prepared in Example 2 was not added; instead, an equal part by weight of microsilica powder was added.
[0029] Comparative Example 3 The difference between this comparative example and Example 1 is that the composite foaming agent and hydrogen peroxide solution prepared in Example 3 were not added; instead, an equal part by weight of commercially available hydrogen peroxide-based chemical foaming agent was added.
[0030] test: I. Mortar Workability and Basic Physical Properties Testing 1. Wet apparent density: According to JGJ / T 70-2009, it reflects the degree of lightweighting of premixed mortar and the stability of aggregate suspension.
[0031] 2.28d dry density and compressive strength: Test blocks were prepared and cured for 28 days according to JGJ / T 70-2009. The density after 28 days of drying, the compressive strength after 7 days and the compressive strength after 28 days were tested to evaluate the lightweight and high-strength properties of the mortar.
[0032] 3. Tensile bond strength: The bond strength between the mortar and the concrete substrate was tested according to JGJ / T 70-2009 to assess its risk of delamination and detachment as a plastering material.
[0033] The test results are shown in Table 1.
[0034] II. Functional Performance Testing 4. Thermal conductivity: The thermal insulation performance of the mortar is evaluated by testing according to GB / T 10294-2008 Determination of steady-state thermal resistance and related properties of thermal insulation materials by the protective hot plate method.
[0035] 5. Weighted impact sound improvement (ΔLw): According to GB / T 19889.8-2006 Acoustics of buildings and building components - Part 8: Laboratory measurement of impact sound improvement of heavy standard floor slab cladding, the sound insulation performance of a 20mm thick mortar layer coated on a standard concrete floor slab was tested, with a focus on its improvement effect on low-frequency impact sound.
[0036] 6. Impact resistance: Referring to the falling ball method, the maximum impact energy that the mortar coating surface can withstand under impact without cracking or peeling is tested to evaluate its toughness and crack resistance.
[0037] The test results are shown in Table 1.
[0038] III. Summary of Results Table 1
[0039] IV. Discussion of Results As shown in Table 1, the green sound insulation and thermal insulation mortars prepared in Examples 1-3 of this invention have excellent and balanced comprehensive performance. While achieving low dry density and good thermal insulation, the mortars have high compressive strength, excellent bonding strength and impact toughness, and significantly improve the impact sound of floor slabs. Moreover, the freshly mixed mortars all show good workability and aggregate suspension stability.
[0040] Compared to Examples 1-3, Comparative Example 1 exhibited the best dry density and thermal conductivity, but its compressive strength, bond strength, and impact resistance all showed a sharp decline, and its improvement in impact sound was also the lowest. This indicates that although unmodified EPS particles may minimize density and thermal conductivity, their smooth, hydrophobic surface results in poor adhesion to the cement matrix, and their low strength makes them unable to effectively transfer and dissipate stress and sound energy, leading to a deterioration in the mechanical properties, durability, and functional properties of the mortar.
[0041] Compared to Examples 1-3, the performance of Comparative Example 2 decreased across the board. Its dry density increased, thermal conductivity increased, and compressive strength, bond strength, impact resistance, and sound insulation were all significantly lower than those of the Examples. This indicates that although single microsilica powder has a micro-filling effect, it lacks the active Al2O3 source provided by calcined kaolin in the silicon-aluminum based active activating admixture system, and also lacks the deep synergistic activation effect of composite activators (sodium sulfate, triethanolamine) on the silicon-aluminum phase.
[0042] Compared to Examples 1-3, Comparative Example 3, at a similar level of lightweighting, exhibits significantly lower compressive strength, bond strength, impact resistance, and sound insulation. Traditional hydrogen peroxide foaming agents have a rapid gas evolution rate and are difficult to control, easily forming interconnected pores with uneven pore size and fragile structures. These pores become stress concentration points and sound bridges, weakening the overall performance.
[0043] In the description of this specification, the references to terms such as "an embodiment," "example," "specific example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.
[0044] The above description is merely an example and illustration of the present invention. Those skilled in the art can make various modifications or additions to the specific embodiments described, or use similar methods to replace them, as long as they do not deviate from the scope defined by the invention, and all such modifications and additions should fall within the protection scope of the present invention.
Claims
1. A green acoustic insulation thermal insulation mortar, characterized in that: By weight parts include the following raw materials: Sulfoaluminate cement 280-320 parts; Grade II fly ash 40-60 parts; Epoxy resin modified EPS composite lightweight aggregate 80-100 parts; Silicon-aluminum-based active activation admixture 70-90 parts; Closed-cell expanded vitrified microsphere 60-80 parts; Redispersible latex powder 15-20 parts; Hydroxypropyl methylcellulose ether 1.8-2.2 parts; Composite foaming agent 2.5-3.5 parts; Polypropylene fiber 0.8-1.2 parts; Starch ether 0.5-0.7 parts; Polycarboxylic acid type water reducing agent 0.7-0.9 parts; Water 150-180 parts; Hydrogen peroxide solution 20-30 parts.
2. The green sound insulation and heat preservation mortar according to claim 1, characterized in that: The preparation method of the epoxy resin modified EPS composite lightweight aggregate is as follows: A1, sieve the waste EPS foam, collect the EPS primary particles with a particle size of 0.6-1.2 mm, and dry at 40-55℃ for 2-3h; A2, in a reaction kettle, add bisphenol A type epoxy resin E-51 and acetone, stir until completely dissolved; under continuous stirring, add ultra-fine quartz powder, disperse uniformly, then add polyamide curing agent, stir to form a coating slurry; The silica content of the ultra-fine quartz powder is not less than 99%, and the particle size is 300-500 mesh; The polyamide curing agent is 650 low molecular polyamide, and the amine value is 200-240mgKOH / g; The mass ratio of bisphenol A type epoxy resin E-51, acetone, ultra-fine quartz powder and polyamide curing agent is 100:15:30:18; A3, the EPS primary particles obtained in step A1 are put into the fluidized bed coating device, the fluidized bed inlet temperature is set to 50-60°C, the air valve is adjusted to make the fluidized air volume reach 100-140 m 3 / h, the atomization pressure is set to 0.2-0.4 MPa; the coating slurry obtained in step A2 is added to the storage tank, the metering pump delivery rate is set to 17.5-23.5 g / min, the spraying is continuously performed for 15-20 min, after the spraying is completed, the original operation parameters are maintained for 5 min, the spraying system and the fluidized air blower are closed, the material is dried at 80°C for 60 min, and then naturally cooled to room temperature, and then sieved to obtain epoxy resin modified EPS composite lightweight aggregate with a particle size of 0.7-1.3 mm.
3. The green sound insulation and heat preservation mortar according to claim 2, characterized in that: In the A1 step, the raw material of the waste EPS foam is a polystyrene foam box obtained by mechanical crushing and 5-15℃ grinding.
4. The green sound insulation and heat preservation mortar according to claim 2, characterized in that: In the A3 step, the mass ratio of the EPS primary particles and the coating slurry is 1:(0.3-0.4).
5. The green sound insulation and heat preservation mortar according to claim 1, characterized in that: The preparation method of the silicon-aluminum-based active activation admixture is as follows: B1, put the microsilica powder and calcined kaolin into a planetary ball mill, add zirconium oxide grinding balls, and grind at a speed of 200-400r / min for 40-50min to obtain a composite ultra-fine powder; The specific surface area of the microsilica is not less than 15000 m 2 / kg; The calcined kaolin is coal-based kaolin calcined at 700-800℃ for 2-3h; The mass ratio of the microsilica powder and the calcined kaolin is 3:2; B2, add the composite ultra-fine powder obtained in step B1, anhydrous sodium sulfate powder and triethanolamine to a high-efficiency mixer, seal and mix for 10-20min to obtain a mixture; B3, place the mixture in a sealed container, let it stand at room temperature for 24-48h, dry and seal to obtain the silicon-aluminum-based active activation admixture.
6. A green soundproofing and heat-insulating mortar according to claim 5, characterized in that: In the B2 step, the mass ratio of the composite ultra-fine powder, anhydrous sodium sulfate powder and triethanolamine is 195:4:
1.
7. The green sound insulation and heat preservation mortar according to claim 1, characterized in that: The preparation method of the composite foaming agent is as follows: C1, take the porous silicon-aluminum carrier microspheres into the impregnation tank; manganese nitrate and copper nitrate are dissolved in deionized water to prepare a mixed solution 1 with a total metal ion concentration of 0.5 mol / L, and the porous silicon-aluminum carrier microspheres are impregnated with the mixed solution 1 in an equal volume under stirring, and then the mixture is left to stand at 25°C for 12 h, dried at 110°C for 6-8 h, and then placed in a muffle furnace and calcined at 330-380°C in an air atmosphere for 3 h, and then cooled to room temperature to obtain an intermediate A; C2, the intermediate A prepared in step C1 is placed in a second impregnation tank, and aluminum sulfate and polyvinyl alcohol are dissolved in deionized water at 60°C to prepare a mixed solution 2 with a concentration of 20%, which is added to the intermediate A prepared in step C1 in an equal volume under stirring, and then the mixture is left to stand at 25°C for 6 h, and then vacuum dried at 80°C for 10-12 h to obtain an intermediate B; The mass ratio of the aluminum sulfate to the polyvinyl alcohol is 5:1; C3, the intermediate B prepared in step C2 and hydrophobic nano-silicon dioxide are added together into a low-speed mixer, mixed at a speed of 15-20 r / min at room temperature for 40-50 min, and then discharged to obtain the composite foaming agent; The mass ratio of the intermediate B to the hydrophobic nano-silicon dioxide is 50:
1.
8. A green soundproofing thermal insulation mortar according to claim 7, characterized in that: In step C1, the mass ratio of the manganese nitrate to the copper nitrate is (265-275):(9-10).
9. The green soundproofing and heat-insulating mortar according to claim 7, characterized in that: In the C1 step, the porous silicon-aluminum carrier microspheres have a particle size of 50-150 μm, a specific surface area of not less than 350 m 2 / g, and a pore size of 2-50 nm.
10. A method for the preparation of the green acoustic insulating thermal insulation mortar according to any one of claims 1-9, characterized by: The specific preparation steps are as follows: S1, the sulfoaluminate cement, grade II fly ash, silicon-aluminum-based active excitation admixture, redispersible latex powder, hydroxypropyl methylcellulose ether, starch ether, and polycarboxylic acid-based water reducing agent are added together into a gravity-free mixer and mixed at a speed of 25-35 r / min for 5-8 min to prepare a premixed cementitious dry powder; S2, the epoxy resin modified EPS composite lightweight aggregate, closed-cell expanded vitrified microsphere, and polypropylene fiber are sequentially added to the premixed cementitious dry powder prepared in step S1, and mixed at a speed of 15-20 r / min for 4-5 min to obtain a finished dry-mixed mortar; S3, at the construction site, water is added to a mortar mixer, and the finished dry-mixed mortar prepared in step S2 is added thereto under stirring at a speed of 200-300 r / min for 1-2 min, and then the composite foaming agent and hydrogen peroxide solution with a concentration of 0.5-2% are added thereto under stirring at a speed of 400-600 r / min for 10-60 s to obtain the product.