High-strength lightweight gypsum-based fireproof thermal insulation material and application thereof

Abstract

The application discloses a kind of high-strength light gypsum-based fireproof thermal insulation materials and its application, belong to building material technical field, by gypsum cementing material, light functional aggregate, reinforcing fiber and admixture composition;The light functional aggregate includes hydrophobic silica aerogel particles and surface modified recycled rubber particles.The high-strength light gypsum-based fireproof thermal insulation material provided by the application solves the performance contradiction of traditional gypsum-based material and single modification technology systematically through unique component design and interface regulation, the strength of the plate is ensured by replacing traditional light gypsum material by introducing a large number of light aggregate to reduce density, the nanometer heat insulation of aerogel and the fireproof mechanism of gypsum crystal water are perfectly fused, the combination of the two not only guarantees the absolute fire safety of the material itself, but also effectively delays the temperature rise of the protected structure during fire.

Description

Technical Field

[0001] This invention relates to the field of building materials technology, and in particular to a high-strength, lightweight gypsum-based fireproof and heat-insulating material and its application. Background Technology

[0002] Gypsum-based materials are widely used in building interior walls and insulation systems due to their advantages such as fire resistance, moisture regulation, and good workability. However, traditional gypsum products have drawbacks such as high density, low strength, and limited thermal insulation performance. To improve their performance, common technical approaches include adding lightweight aggregates (such as expanded perlite) to reduce density and thermal conductivity, or adding fibers to enhance toughness. However, these methods often have trade-offs: adding large amounts of lightweight aggregates can significantly reduce strength; simply adding fibers has limited effect on improving thermal insulation.

[0003] In recent years, some studies have attempted to introduce novel lightweight materials such as aerogels or rubber particles into gypsum. Aerogels have extremely low thermal conductivity, but they are expensive, and their compatibility with the gypsum matrix and structural integrity during mixing are technical challenges. On the other hand, incorporating waste rubber particles into gypsum is an effective way to realize the resource utilization of solid waste, and can give the material good elasticity and sound insulation. However, the interfacial bonding between rubber and the inorganic gypsum matrix is ​​extremely poor, which leads to a sharp decrease in the material's strength, limiting its application in high-strength applications.

[0004] Therefore, developing a new type of gypsum-based composite material that can synergistically address multiple needs such as lightweight, high strength, fire resistance, and heat insulation, and realize the high-value utilization of industrial solid waste, has significant technical and economic value. Summary of the Invention

[0005] The purpose of this invention is to address the problem that while incorporating waste rubber particles into gypsum is an effective way to achieve solid waste resource utilization and can give the material good elasticity and sound insulation, the poor interfacial bonding between rubber and inorganic gypsum matrix leads to a sharp decrease in material strength, limiting its application in high-strength scenarios. Therefore, this invention proposes a high-strength lightweight gypsum-based fireproof and heat-insulating material and its application.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A high-strength, lightweight gypsum-based fireproof and heat-insulating material, composed of gypsum cementitious material, lightweight functional aggregate, reinforcing fiber and additives; The lightweight functional aggregate comprises hydrophobic silica aerogel particles and surface-modified recycled rubber particles. The gypsum cementitious material, in 100 parts by weight, comprises: 5-25 parts of surface-modified recycled rubber particles, 1-15 parts of hydrophobic silica aerogel particles, 0.5-8 parts of reinforcing fibers, and 0.5-10 parts of additives.

[0007] As a preferred embodiment, the surface-modified reclaimed rubber particles are obtained by surface treatment of waste rubber powder with a particle size of 40-80 mesh using a silane coupling agent.

[0008] As a preferred embodiment, the specific steps of the surface treatment are as follows: first, the waste rubber powder is cleaned with anhydrous ethanol to remove surface impurities, and after drying, it is impregnated or sprayed with an ethanol solution of silane coupling agent KH550 or KH570, and finally dried.

[0009] As a preferred embodiment, the hydrophobic silica aerogel particles have a particle size of 10-100 mesh and a porosity greater than 90%, and their incorporation makes the thermal conductivity of the material less than 0.08 W / (m·K).

[0010] As a preferred embodiment, the reinforcing fiber is at least one of polyvinyl alcohol fiber, polypropylene fiber, glass fiber, or carbon fiber with a length of 3-15 mm.

[0011] As a preferred embodiment, the material further includes redispersible latex powder comprising 0.5%-5% of the weight of the gypsum cementitious material.

[0012] A method for preparing high-strength, lightweight gypsum-based fireproof and heat-insulating materials includes the following steps: S1. Surface modification treatment of recycled rubber particles; S2. The modified recycled rubber particles, aerogel particles, reinforcing fibers and gypsum cementitious materials are premixed evenly. S3. Dissolve the additive in water to form a mixture; S4. Add the mixture to the dry mixture in S2 and stir to form a uniform slurry; S5. The slurry is injected into the mold, and the product is obtained after vibration, molding, natural curing and drying.

[0013] Application of a high-strength, lightweight gypsum-based fireproof and heat-insulating material in the preparation of non-load-bearing partition walls, fireproof, heat-insulating and decorative integrated panels, or fireproof protective layers for steel structures; The core layer is made of high-strength, lightweight gypsum-based fireproof and heat-insulating material.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: 1. The high-strength lightweight gypsum-based fireproof and heat-insulating material provided by this invention, through unique component design and interface control, systematically solves the performance contradictions that traditional gypsum-based materials and single modification technologies have long faced, achieving significant and unexpected technological progress. This invention replaces the traditional lightweight gypsum material that reduces density by introducing a large amount of lightweight aggregate through the synergistic architecture of "composite functional aggregate" and "multi-scale reinforcement", ensuring the strength of the board.

[0015] 2. This invention addresses the problem that conventional thermal insulation materials, while offering good insulation, have low fire resistance, while fire-resistant materials suffer from high density and hygroscopicity. It perfectly integrates the nano-insulation properties of aerogel with the fire-retardant mechanism of gypsum's water of crystallization. The nanoporous structure of aerogel effectively inhibits air convection and heat conduction, resulting in a composite material with a stable thermal conductivity below 0.08. Gypsum releases water of crystallization to absorb heat when exposed to fire. Both aerogel and gypsum are Class A non-combustible materials. The combination of these two materials not only ensures absolute fire safety but also effectively delays the temperature rise of the protected structure during a fire due to their excellent insulation properties. Attached Figure Description

[0016] Figure 1 This is a flowchart illustrating the preparation method of a high-strength, lightweight gypsum-based fireproof and heat-insulating material proposed in this invention. Detailed Implementation

[0017] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the scope of protection of the present invention.

[0018] It should be understood that, when used in this specification and the appended claims, the terms "comprising" and "including" indicate the presence of the described features, integrals, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or collections thereof.

[0019] It should also be understood that the terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention. As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise.

[0020] It should also be further understood that the term "and / or" as used in this specification and the appended claims refers to any combination of one or more of the associated listed items and all possible combinations, and includes such combinations.

[0021] Reference Figure 1 A high-strength, lightweight gypsum-based fireproof and heat-insulating material and its application, comprising gypsum cementitious material, lightweight functional aggregate, reinforcing fiber and additives; The lightweight functional aggregates consist of hydrophobic silica aerogel particles and surface-modified recycled rubber particles; The gypsum cementitious material, by weight, comprises: 5-25 parts of surface-modified recycled rubber particles, 1-15 parts of hydrophobic silica aerogel particles, 0.5-8 parts of reinforcing fibers, and 0.5-10 parts of additives.

[0022] Surface-modified reclaimed rubber granules are obtained by surface treatment of waste rubber powder with a particle size of 40-80 mesh using a silane coupling agent.

[0023] The specific steps of surface treatment are as follows: First, the waste rubber powder is cleaned with anhydrous ethanol to remove surface impurities. After drying, it is impregnated or sprayed with an ethanol solution of silane coupling agent KH550 or KH570, and finally dried.

[0024] The hydrophobic silica aerogel particles have a particle size of 10-100 mesh and a porosity greater than 90%. Their incorporation reduces the thermal conductivity of the material to less than 0.08 W / (m·K).

[0025] The reinforcing fiber is at least one of polyvinyl alcohol fiber, polypropylene fiber, glass fiber or carbon fiber with a length of 3-15 mm.

[0026] The materials also include redispersible latex powder, which accounts for 0.5%-5% of the weight of the gypsum cementitious material.

[0027] A method for preparing a high-strength, lightweight gypsum-based fireproof and heat-insulating material includes the following steps: The first step is to perform surface modification treatment on the recycled rubber granules; The second step is to premix the modified recycled rubber granules, aerogel granules, reinforcing fibers and gypsum cementitious materials evenly. The third step is to dissolve the additive in water to form a mixture. Step 4: Add the mixture to the dry mix of S2 and stir to form a uniform slurry; Step 5: Pour the slurry into the mold, and after vibration, molding, natural curing and drying, the product is obtained; Based on the above, the material has the following characteristics: Lightweight and thermally insulating: The dry density of the composite material can be controlled between 400-800 kg / m³. 3 The thermal conductivity can be lower than 0.08 W / (m·K), which is significantly better than traditional gypsum products.

[0028] Balance between strength and toughness: Through interface modification and fiber reinforcement, the compressive strength after 28 days can reach more than 5.0 MPa, while also possessing high fracture toughness and flexural strength.

[0029] Fire prevention and environmental protection: Both gypsum and aerogel are Class A non-combustible materials; a large amount of recycled rubber and industrial by-product gypsum are used, resulting in a high utilization rate of solid waste; This invention replaces the traditional lightweight gypsum material that reduces density by introducing a large amount of lightweight aggregate through a synergistic architecture of "composite functional aggregate" and "multi-scale reinforcement", thus ensuring the strength of the board.

[0030] The specific implementation method is as follows: Example 1 Formula: 100 parts building plaster, 10 parts 40-mesh rubber granules modified with KH550, 3 parts aerogel granules, 1 part polyvinyl alcohol fiber, 0.5 parts polypropylene fiber, 0.3 parts water-reducing agent, 0.1 parts hydroxypropyl methylcellulose ether, 1 part redispersible latex powder, and 45 parts water.

[0031] Preparation and Testing: The product was molded, cured, and tested according to the aforementioned preparation method. The dry density was measured to be 580 kg / m³. 3 The thermal conductivity is 0.065 W / (m·K), and the 28-day compressive strength is 7.2 MPa.

[0032] Example 2 Formula: 100 parts building plaster, 15 parts 40-mesh rubber granules modified with KH550, 5 parts aerogel granules, 1.5 parts polyvinyl alcohol fiber, 1 part polypropylene fiber, 0.5 parts water-reducing agent, 0.15 parts hydroxypropyl methylcellulose ether, 1.5 parts redispersible latex powder, and 50 parts water.

[0033] Preparation and testing: The method was the same as in Example 1. The dry density was measured to be 520 kg / m³. 3 The thermal conductivity is 0.058 W / (m·K), and the 28-day compressive strength is 6.3 MPa.

[0034] Example 3 Formula: Desulfurized gypsum completely replaces building gypsum, otherwise the same as in Example 2.

[0035] Preparation and testing: The method was the same as in Example 1. The dry density was measured to be 530 kg / m³. 3 The thermal conductivity is 0.060 W / (m·K), and the 28-day compressive strength is 6.0 MPa. This proves that industrial by-product gypsum is entirely feasible.

[0036] Comparative Example 1 The formulation and preparation method are the same as in Example 2, but aerogel particles are not added, and an equal volume of gypsum powder is added accordingly.

[0037] Test results: Dry density is 750 kg / m³ 3 The thermal conductivity is 0.135 W / (m·K), and the compressive strength is 7.8 MPa. This indicates that aerogels make a significant contribution to reducing density and thermal conductivity.

[0038] Comparative Example 2 The formulation and preparation method are the same as in Example 2, but the rubber particles are only washed with water and no silane coupling agent is used.

[0039] Test results: Dry density is 515 kg / m³ 3 The thermal conductivity is 0.059 W / (m·K), but the 28-day compressive strength is only 3.1 MPa, and failure is mostly due to debonding at the rubber-plaster interface. This contrast strongly demonstrates the crucial role of surface modification treatment in ensuring material strength.

[0040] Formulation table corresponding to the embodiments Application examples of the present invention The slurry obtained in Example 2 was injected into a standard wall panel mold (e.g., 2440mm×610mm×60mm), and after vibration, curing, and drying, a lightweight partition wall panel was produced. The material was tested by a building materials testing center and its surface density was ≤65kg / m³. 2 Fire resistance limit ≥2.5 hours, sound insulation ≥40dB, all indicators are better than the national standard requirements for gypsum hollow core slabs; The nano-insulation of aerogel and the fire-retardant mechanism of gypsum's water of crystallization are perfectly integrated. The nanoporous structure of aerogel effectively inhibits air convection and heat conduction, making the thermal conductivity of the composite material consistently below 0.08. Gypsum releases water of crystallization to absorb heat when exposed to fire. Both aerogel and gypsum are Class A non-combustible materials. The combination of the two not only ensures the absolute fire safety of the materials themselves, but their excellent thermal insulation properties can also effectively delay the temperature rise of the protected structure during a fire.

[0041] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A high-strength, lightweight gypsum-based fireproof and heat-insulating material, characterized in that, It is composed of gypsum cementitious materials, lightweight functional aggregates, reinforcing fibers, and additives; The lightweight functional aggregate comprises hydrophobic silica aerogel particles and surface-modified recycled rubber particles. The gypsum cementitious material, in 100 parts by weight, comprises: 5-25 parts of surface-modified recycled rubber particles, 1-15 parts of hydrophobic silica aerogel particles, 0.5-8 parts of reinforcing fibers, and 0.5-10 parts of additives.

2. The high-strength, lightweight gypsum-based fireproof and heat-insulating material according to claim 1, characterized in that, The surface-modified reclaimed rubber particles are obtained by surface treatment of waste rubber powder with a particle size of 40-80 mesh using a silane coupling agent.

3. The high-strength, lightweight gypsum-based fireproof and heat-insulating material according to claim 1, characterized in that, The specific steps of the surface treatment are as follows: first, the waste rubber powder is cleaned with anhydrous ethanol to remove surface impurities, and after drying, it is impregnated or sprayed with an ethanol solution of silane coupling agent, and finally dried.

4. The high-strength, lightweight gypsum-based fireproof and heat-insulating material according to claim 1, characterized in that, The hydrophobic silica aerogel particles have a particle size of 10-100 mesh and a porosity greater than 90%, and their incorporation reduces the thermal conductivity of the material to less than 0.08 W / (m·K).

5. The high-strength, lightweight gypsum-based fireproof and heat-insulating material according to claim 1, characterized in that, The reinforcing fiber is at least one of polyvinyl alcohol fiber, polypropylene fiber, glass fiber, or carbon fiber with a length of 3-15 mm.

6. The high-strength, lightweight gypsum-based fireproof and heat-insulating material according to claim 1, characterized in that, The material also includes redispersible latex powder comprising 0.5%-5% of the weight of the gypsum cementitious material.

7. A method for preparing a high-strength, lightweight gypsum-based fireproof and heat-insulating material according to any one of claims 1-6, characterized in that, Includes the following steps: S1. The recycled rubber particles are subjected to the surface modification treatment as described in claim 4; S2. The modified recycled rubber particles, aerogel particles, reinforcing fibers and gypsum cementitious materials are premixed evenly. S3. Dissolve the additive in water to form a mixture; S4. Add the mixture to the dry mixture in S2 and stir to form a uniform slurry; S5. The slurry is injected into the mold, and the product is obtained after vibration, molding, natural curing and drying.

8. The application of a high-strength lightweight gypsum-based fireproof and heat-insulating material as described in any one of claims 1-6 in the preparation of non-load-bearing partition walls, fireproof and heat-insulating integrated decorative panels, or fireproof protective layers for steel structures; The core layer is made of high-strength, lightweight gypsum-based fireproof and heat-insulating material.

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