Reinforced environment-friendly light partition wall plate

Abstract

This invention discloses a reinforced, environmentally friendly, lightweight partition wall panel, relating to the field of lightweight partition wall panel preparation technology. The raw materials, by weight, include 40 to 55 parts ordinary silicate cement, 15 to 25 parts modified desulfurized gypsum slag, 5 to 12 parts recycled polystyrene particles, 3 to 8 parts composite fiber, 0.5 to 2 parts water-reducing agent, 0.2 to 1 part silane coupling agent, 0.1 to 0.5 parts air-entraining agent, and 20 to 30 parts water. The modified desulfurized gypsum slag is obtained by drying, dehydrating, low-temperature calcining, and surface modification with a silane coupling agent from thermal power plant desulfurized gypsum. The composite fiber is obtained by blending basalt short-cut fibers and polyacrylonitrile fibers in a 1:2 mass ratio. The preparation process includes pre-treating the composite fiber with antistatic agents. This invention uses a blend of recycled polystyrene particles and modified desulfurized gypsum slag as lightweight aggregate, completely replacing natural virgin aggregate, significantly improving solid waste utilization, reducing raw material procurement costs, and forming a three-dimensional bonded network within the matrix of the composite fiber, thus improving flexural and impact resistance.

Description

Technical Field

[0001] This invention relates to the field of lightweight partition wall panel manufacturing technology, and in particular to a reinforced environmentally friendly lightweight partition wall panel. Background Technology

[0002] Lightweight partition wall panels are a core supporting material for non-load-bearing interior partition walls in prefabricated buildings. They are widely used in interior partitioning projects of residential buildings, commercial complexes, public venues, and other buildings. As the penetration rate of prefabricated buildings in China increases year by year, the industry has put forward higher requirements for the mechanical properties, environmental protection attributes, cost control, and low carbon attributes of lightweight partition wall panels. The core requirements focus on four dimensions: high strength and crack resistance, low water absorption and water resistance, high utilization rate of solid waste resources, and uniform performance of batches.

[0003] Currently, the mainstream cement-based lightweight partition wall panels on the market use ordinary Portland cement as the cementing material and natural minerals such as virgin ceramsite and expanded perlite as lightweight aggregates. They are prepared by mixing, molding, and natural curing with ordinary water-reducing agents. This technology is mature, has a low entry barrier, and currently accounts for more than 60% of the domestic lightweight partition wall panel market. Its advantages lie in the availability of raw materials, short production cycle, and basic compliance with the fundamental requirements of conventional buildings. However, this technology has significant drawbacks: the procurement cost of virgin lightweight aggregates is high, there is no industrial solid waste disposal capacity, and it does not meet the requirements of low-carbon development; the interfacial bonding between aggregates and cement matrix is ​​weak, resulting in low overall mechanical properties, with conventional products having a flexural strength of less than 2.2 MPa, making them prone to cracking, breakage, and corner chipping during use; the water absorption rate of the products generally exceeds 20%, resulting in poor water resistance and durability, and easy strength decay and pulverization in humid environments.

[0004] Another mainstream type of gypsum-based lightweight partition wallboard uses building gypsum as the main cementing material and is prepared through physical foaming. Its advantages are its light weight, good sound insulation performance, and slightly lower production cost than cement-based products. Currently, it accounts for about 30% of the market. However, this technology also has its shortcomings: gypsum itself is highly hydrophilic, and the product has extremely poor water resistance. It easily softens and powders when exposed to water, making it unsuitable for use in damp areas such as kitchens and bathrooms, requiring additional waterproofing treatment and increasing construction costs; its overall mechanical properties are also weaker, with a flexural strength of less than 1.8 MPa, and the breakage rate during transportation and installation is as high as 15% or more; its production consumes natural gypsum resources, resulting in extremely low solid waste disposal capacity.

[0005] Currently, a small number of companies in the industry have attempted to use industrial solid waste to replace virgin aggregates, but none of them have solved the problem of the interface bonding between solid waste aggregates and cementitious matrix. Directly added solid waste is prone to problems such as stratification and rapid strength decay. If fibers are added to improve strength, fiber agglomeration and poor uniformity of performance of batch products are likely to occur, making it impossible to achieve large-scale stable production and difficult to meet the high-quality development needs of prefabricated buildings. Summary of the Invention

[0006] To address the problems of existing lightweight partition wall panels, such as high consumption of virgin aggregate, poor mechanical and water resistance properties, easy fiber agglomeration, and poor batch performance stability, this invention provides a reinforced environmentally friendly lightweight partition wall panel.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: a reinforced environmentally friendly lightweight partition wall panel, belonging to inorganic composite building wall materials, wherein all raw materials meet the environmental emission requirements for building materials, and is prepared by accurately measuring the following raw material components by weight: The composition comprises 25-40 parts cementitious material, 30-45 parts composite recycled lightweight aggregate, 2-8 parts composite fiber reinforcing component, 1-5 parts modifying agent, and 10-18 parts deionized water. The composite recycled lightweight aggregate is a homogeneous aggregate obtained by mixing recycled polystyrene particles and modified desulfurized gypsum slag in a preset ratio. The bulk density of the composite recycled lightweight aggregate is controlled at 280-420 kg / m³, and the particle size range of a single particle is 0.1-3 mm. The composite fiber reinforcing component is a homogeneous fiber mixture obtained by mixing basalt chopped fibers and polyacrylonitrile fibers in a preset ratio. The tensile strength of each filament of the composite fiber reinforcing component is not less than 500 MPa, and there are no defects such as agglomeration or excessive impurities.

[0008] Preferably, the cementitious material is a homogeneous mixture of sulfoaluminate cement, metakaolin, and silica fume in a mass ratio of 5:2:1. The sulfoaluminate cement has a grade of not less than 42.5 and an initial setting time of 25-40 min. The metakaolin has a mesh size of not less than 1250 mesh, and the silica fume has a silica content of not less than 92 wt%. All three raw materials are dried before mixing, with a moisture content of not more than 0.5 wt%. The mixing process is carried out in a closed mixing device with a mixing speed of 300 r / min and a mixing time of 4 min to ensure a mixing uniformity of not less than 98%.

[0009] Preferably, the mass ratio of recycled polystyrene particles to modified desulfurized gypsum slag in the composite recycled lightweight aggregate is 1:3-5. The recycled polystyrene particles are homogeneous particles obtained by crushing, screening, and removing impurities from waste polystyrene insulation boards, with a single particle size of 0.1-2 mm and a bulk density of 80-120 kg / m³. The modified desulfurized gypsum slag is industrial solid waste desulfurized gypsum slag from the thermal power industry that has undergone surface modification treatment with a silane coupling agent. The interfacial bonding strength between the modified desulfurized gypsum slag and the cementitious material is increased by no less than 30% compared with the unmodified sample, and the water absorption rate is reduced by no less than 25%.

[0010] Preferably, in the composite fiber reinforcement component, the length of the basalt chopped fibers is 6-12 mm and the diameter of the single filament is 10-18 μm, the length of the polyacrylonitrile fibers is 3-8 mm and the diameter of the single filament is 8-15 μm, and the mass ratio of the two is 2:1-2; the basalt chopped fibers and polyacrylonitrile fibers are both treated with antistatic agents before mixing to avoid fiber agglomeration, and the fiber dispersion after mixing is not less than 95%, which can be uniformly dispersed in the matrix material during subsequent stirring to form a three-dimensional network reinforcement structure.

[0011] Preferably, the modified additive is a homogeneous mixture obtained by mixing polycarboxylate superplasticizer, calcium stearate foaming regulator, sodium citrate retarder, and KH550 silane coupling agent in a mass ratio of 3:2:1:1. The water reduction rate of the polycarboxylate superplasticizer is not less than 28%, the fineness of the calcium stearate is not less than 200 mesh, and the purity of the sodium citrate is not less than 98 wt%. The four additives are sealed and stored after mixing to avoid moisture and failure. Before use, the content of the effective ingredients must be tested to be not less than 97% of the nominal value.

[0012] Preferably, a method for preparing the reinforced environmentally friendly lightweight partition wall panel, wherein all preparation steps meet the environmental protection emission requirements for building material production, and there is no emission of toxic or harmful waste gas or waste residue, specifically includes the following steps: S1. Accurately weigh all raw material components according to the preset weight parts. First, put the pre-dried cementitious material and composite recycled lightweight aggregate into a vertical mixing kettle with a forced stirring structure. Stir at 300-400r / min for 3-5min at room temperature and pressure. During the stirring process, ultrasonic dispersion treatment is carried out simultaneously at an ultrasonic frequency of 20kHz to ensure that the two aggregates and cementitious material are initially mixed evenly to obtain a first mixture without stratification or agglomeration. S2. Evenly sprinkle the composite fiber reinforcing component and modifying agent into the first mixture in the mixing tank, increase the stirring speed to 450-600 r / min and continue stirring for 6-10 min. During the stirring process, add all the metered deionized water at a constant rate. After the water is added, continue stirring for 2 min to finally obtain the second mixture with a flowability of 180-220 mm, no fiber clumps and no agglomerates. S3. The second mixture is injected at a uniform speed into the steel partition wall panel mold of the corresponding specification. After being vibrated and formed by a vibrating table, it is sent to an atmospheric pressure curing chamber for static curing for 12-18 hours. After demolding, it is sent to a steam curing kiln for steam curing for 24-36 hours. After curing, it is taken out and sent to a room temperature storage area for natural storage for 7 days. After passing the appearance and strength tests, the reinforced environmentally friendly lightweight partition wall panel is obtained.

[0013] Preferably, the pretreatment step of the modified desulfurized gypsum slag in S1 is as follows: the industrial solid waste desulfurized gypsum slag discharged from the thermal power industry is first calcined to remove the crystal water. The calcination temperature is 150-180℃ and the calcination time is 2h. After calcination, it is cooled to room temperature, crushed and screened to a particle size of 0.5-3mm, and then soaked in a 1.5wt% KH550 silane coupling agent ethanol solution for 30min. During the soaking process, the mixture is continuously stirred to ensure that the silane coupling agent fully contacts the surface of the gypsum slag. After soaking, the excess solution is removed by filtration. The filtered gypsum slag is placed in a 105℃ forced-air drying oven and dried to constant weight. After cooling to room temperature, the modified desulfurized gypsum slag is obtained. The interfacial bonding strength between the gypsum slag and the cement matrix is ​​tested to be no less than 1.2MPa.

[0014] Preferably, the stirring speed in S2 is stably controlled at 450-600 r / min, the stirring process is kept sealed throughout to prevent dust from overflowing, the water addition rate is precisely controlled at 1.2-1.8 L / min, the water inlet is set at the center of the mixing vessel to ensure that the water can evenly contact all the mixture, and the fiber dispersion is checked every 2 minutes during the stirring process to ensure that there is no fiber agglomeration or clumping throughout the stirring process, and the fiber dispersion of the final second mixture is not less than 95%.

[0015] Preferably, the vibration molding parameters in S3 are as follows: the vibration frequency of the vibration table is stably controlled at 50-60Hz, the amplitude is controlled at 0.8-1.2mm, the vibration time is 2-4min, the mixture on the mold surface is scraped smooth every 30s during the vibration process to ensure that the mixture completely fills all corners of the mold, the residual air bubbles inside the mixture are removed simultaneously during the vibration process, and the porosity of the final molded blank is controlled at 15-22%, and the pores are all uniformly distributed closed-cell structures.

[0016] Preferably, the steam curing parameters in S3 are as follows: the temperature of the steam curing kiln is controlled by a stepped heating method with a heating rate of 10℃ / h, and the final curing temperature is stably controlled at 60-80℃. The relative humidity of the curing environment is maintained above 90% throughout the process. After steam curing, the temperature is cooled to room temperature by a stepped cooling method with a cooling rate of 8℃ / h. Sudden temperature rises and falls are avoided throughout the curing process to prevent cracking and deformation defects in the billet. The flexural strength of the partition wall plate billet after curing is not less than 3.5MPa, and the compressive strength is not less than 5MPa.

[0017] The present invention has the following beneficial effects: This invention utilizes a composite recycled lightweight aggregate made from recycled polystyrene particles and modified desulfurized gypsum slag, which completely replaces the natural lightweight aggregate used in existing technologies. This enables the high-value utilization of two types of industrial solid waste, effectively reducing raw material procurement costs. At the same time, it can be compatible with the production process of the original production line without modifying existing production equipment, which is in line with the policy orientation of low-carbon and circular development of building materials. It effectively solves the shortcomings of existing technologies, such as large consumption of virgin aggregate, low level of solid waste resource utilization, and high production costs.

[0018] This invention utilizes a composite reinforcement system of basalt short-cut fibers and polyacrylonitrile fibers of varying lengths to form a three-dimensional interwoven network within the cementitious matrix. This significantly improves the product's flexural and impact resistance, reduces drying shrinkage, and fundamentally prevents cracking, breakage, and corner chipping during use. Simultaneously, it modifies the surface of desulfurized gypsum slag using a silane coupling agent, introducing active groups that can bind with cement hydration products onto the surface of the solid waste aggregate. This enhances the interfacial bonding strength between the aggregate and the cementitious matrix, while reducing the aggregate's surface hydrophilicity, significantly decreasing the product's water absorption rate, and improving long-term water resistance and durability. This effectively solves the shortcomings of existing technologies, such as insufficient mechanical properties, poor water resistance, and short service life.

[0019] This invention utilizes a step-by-step feeding process, ultrasonic-assisted dispersion, and uniform water addition and stirring, combined with pre-treatment of fibers to prevent fiber agglomeration within the matrix. This ensures uniform fiber dispersion, significantly improves the performance uniformity of batch products, avoids performance defects caused by localized stress concentration, and effectively solves the shortcomings of existing technologies, such as easy agglomeration after fiber addition, large performance deviations in batch products, and difficulty in large-scale stable production.

[0020] The reinforced environmentally friendly lightweight partition wall panel prepared by this invention has performance indicators that are superior to the requirements of relevant national standards. It can not only meet the interior partition wall needs of conventional civil buildings, but also be applied to special scenarios such as humid environments and public buildings with high usage intensity. It has a wider range of applications and does not require additional post-processing procedures such as waterproofing and reinforcement, which can effectively reduce the overall cost of construction and has high industry promotion value. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the process for a reinforced environmentally friendly lightweight partition wall panel proposed in this invention; Figure 2 This is a bar chart comparing the mechanical properties of various samples in this invention; Figure 3 This is a bar chart comparing the water absorption rate and bulk density of each sample in this invention; Figure 4 This is a line graph showing the solid waste resource utilization rate of different formulations in this invention; Figure 5This is a bar chart comparing fiber dispersion and molded closed-cell porosity in this invention. Detailed Implementation

[0022] The following will refer to the appendices in the embodiments of the present invention. Figure 1-5 The technical solutions in the embodiments of the present invention are clearly and completely described herein. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0023] Example 1 The raw materials used to prepare the reinforced environmentally friendly lightweight partition wall panel in this embodiment are as follows by weight: 25 parts cementitious material, 30 parts composite recycled lightweight aggregate, 2 parts composite fiber reinforcing component, 1 part modifier, and 10 parts deionized water. The cementitious material is a homogeneous mixture obtained by mixing 42.5 grade sulfoaluminate cement, 1250 mesh metakaolin, and silica fume with a silica content of 92wt% in a mass ratio of 5:2:1. Before mixing, the moisture content of the three raw materials is 0.3wt%. The mixing speed is 300 r / min, the mixing time is 4 min, and the mixing uniformity is 98.5%.

[0024] The composite recycled lightweight aggregate is a homogeneous aggregate obtained by mixing recycled polystyrene particles and modified desulfurized gypsum slag at a mass ratio of 1:3, with a bulk density of 290 kg / m³ and a single particle size range of 0.1-2.8 mm. Recycled polystyrene granules are homogeneous granules obtained from waste polystyrene insulation boards through crushing, screening, and impurity removal. Individual particle sizes are 0.1-2 mm, and bulk density is 100 kg / m³. Modified desulfurization gypsum slag is desulfurization gypsum slag from thermal power plant solid waste that has been modified with a silane coupling agent. The pretreatment steps are as follows: The desulfurized gypsum slag was calcined at 150℃ for 2 hours to remove the water of crystallization. After cooling, it was crushed and sieved to a particle size of 0.5-3 mm. It was then soaked in a 1.5 wt% KH550 silane coupling agent ethanol solution for 30 minutes with continuous stirring during the soaking process. After filtration, it was dried in a 105℃ forced-air drying oven to constant weight. After cooling, the modified desulfurized gypsum slag was obtained, and its interfacial bond strength with the cement matrix was 1.25 MPa.

[0025] The composite fiber reinforcement component is a homogeneous fiber mixture obtained by mixing basalt short chopped fibers with a length of 6 mm and a single filament diameter of 10 μm with polyacrylonitrile fibers with a length of 3 mm and a single filament diameter of 8 μm at a mass ratio of 2:1. Both types of fibers are treated with antistatic agents before mixing. After mixing, the fiber dispersion is 96%, and the tensile strength of each single filament is not less than 520 MPa.

[0026] The modified additive is a homogeneous mixture obtained by mixing polycarboxylate superplasticizer with a water reduction rate of 30%, calcium stearate foaming regulator with a mesh size of 200, sodium citrate retarder with a purity of 98.5wt%, and KH550 silane coupling agent in a mass ratio of 3:2:1:1. The effective component content is 98% before use.

[0027] The preparation steps in this embodiment are as follows: S1. Accurately weigh all raw material components according to the above weight proportions. First, put the pre-dried cementitious material and composite recycled lightweight aggregate into a vertical mixing kettle with a forced stirring structure. Stir at 300r / min for 3 minutes at room temperature and pressure. Simultaneously, perform 20kHz ultrasonic dispersion treatment during the stirring process to obtain a first mixture without stratification or agglomeration.

[0028] S2. Evenly sprinkle the composite fiber reinforcing component and modifying agent into the first mixture in the mixing vessel, increase the stirring speed to 450 r / min and continue stirring for 6 min. During the stirring process, add all the metered deionized water at a constant rate of 1.2 L / min. After the water is added, continue stirring for 2 min. Check the fiber dispersion every 2 min throughout the process. There is no fiber agglomeration or clumping. Finally, the second mixture with a flowability of 185 mm and a fiber dispersion of 95.5% is obtained.

[0029] S3. The second mixture is uniformly injected into a steel partition wall mold of 2440mm×610mm×90mm, and placed on a vibrating table for vibration molding. The vibration frequency is 50Hz, the amplitude is 0.8mm, and the vibration time is 2min. During the vibration process, the mixture on the surface of the mold is scraped flat every 30s to remove residual air bubbles. After molding, the internal porosity of the blank is 21.2%, and the pores are a uniform closed-cell structure. The product was then placed in an atmospheric pressure curing chamber for 12 hours of static curing. After demolding, it was placed in a steam curing kiln and heated to 60°C at a rate of 10°C / h. The relative humidity of the curing environment was maintained at 92%. After steam curing for 24 hours, it was cooled to room temperature at a rate of 8°C / h. After removal, it was placed in a room temperature storage area for natural storage for 7 days. Visual inspection showed no cracks or deformation, thus obtaining the reinforced environmentally friendly lightweight partition wall panel.

[0030] This embodiment addresses the shortcomings of high cost and low utilization rate of virgin aggregates by using composite recycled solid waste aggregates, solves the problem of low strength and easy cracking by forming a three-dimensional reinforcement network with composite fibers of varying lengths, and solves the problems of poor interfacial bonding and fiber agglomeration by using modified desulfurized gypsum and precise mixing parameters.

[0031] Example 2 The raw materials used to prepare the reinforced environmentally friendly lightweight partition wall panel in this embodiment are as follows by weight: 40 parts cementitious material, 45 parts composite recycled lightweight aggregate, 8 parts composite fiber reinforcing component, 5 parts modifier, and 18 parts deionized water. The cementitious material is a homogeneous mixture obtained by mixing 42.5 grade sulfoaluminate cement, 1250 mesh metakaolin, and silica fume with a silica content of 92wt% in a mass ratio of 5:2:1. Before mixing, the moisture content of the three raw materials is 0.28wt%. The mixing speed is 300 r / min, the mixing time is 4 min, and the mixing uniformity is 98.7%.

[0032] The composite recycled lightweight aggregate is a homogeneous aggregate obtained by mixing recycled polystyrene particles and modified desulfurized gypsum slag at a mass ratio of 1:5, with a bulk density of 410 kg / m³ and a single particle size range of 0.2-3 mm; the recycled polystyrene particles are homogeneous particles obtained by crushing, screening and removing impurities from waste polystyrene insulation boards, with a single particle size of 0.1-2 mm and a bulk density of 98 kg / m³. The modified desulfurized gypsum slag is a solid waste desulfurized gypsum slag from thermal power plants that has been modified with a silane coupling agent. The pretreatment steps are as follows: the desulfurized gypsum slag is calcined at 150℃ for 2 hours to remove the water of crystallization, cooled, crushed and screened to a particle size of 0.5-3 mm, soaked in a 1.5 wt% KH550 silane coupling agent ethanol solution for 30 minutes with continuous stirring during the soaking process, filtered, and then dried in a 105℃ forced-air drying oven to constant weight. After cooling, the modified desulfurized gypsum slag is obtained, and its interfacial bonding strength with the cement matrix is ​​1.32 MPa.

[0033] The composite fiber reinforcement component is a homogeneous fiber mixture obtained by mixing basalt short chopped fibers with a length of 12 mm and a single filament diameter of 18 μm with polyacrylonitrile fibers with a length of 8 mm and a single filament diameter of 15 μm at a mass ratio of 2:2. Both types of fibers are treated with antistatic agents before mixing. After mixing, the fiber dispersion is 96.2%, and the tensile strength of each single filament is not less than 510 MPa.

[0034] The modified additive is a homogeneous mixture obtained by mixing polycarboxylate superplasticizer with a water reduction rate of 30%, calcium stearate foaming regulator with a mesh size of 200, sodium citrate retarder with a purity of 98.5 wt%, and KH550 silane coupling agent in a mass ratio of 3:2:1:1. The effective component content is 98.2% before use.

[0035] The preparation steps in this embodiment are as follows: S1. Accurately weigh all raw material components according to the above weight proportions. First, put the pre-dried cementitious material and composite recycled lightweight aggregate into a vertical mixing kettle with a forced stirring structure. Stir at 400r / min for 5 minutes at room temperature and pressure. Simultaneously, perform 20kHz ultrasonic dispersion treatment during the stirring process to obtain a first mixture without stratification or agglomeration.

[0036] S2. Evenly sprinkle the composite fiber reinforcing component and modifying agent into the first mixture in the mixing vessel, increase the stirring speed to 600 r / min and continue stirring for 10 min. During the stirring process, add all the metered deionized water at a constant rate of 1.8 L / min. After the water is added, continue stirring for 2 min. Check the fiber dispersion every 2 min throughout the process. There is no fiber agglomeration or clumping. Finally, the second mixture with a flowability of 215 mm and a fiber dispersion of 95.8% is obtained.

[0037] S3. The second mixture is uniformly injected into a steel partition wall mold of 2440mm×610mm×90mm, and placed on a vibration table for vibration molding. The vibration frequency is 60Hz, the amplitude is 1.2mm, and the vibration time is 4min. During the vibration process, the mixture on the surface of the mold is scraped every 30s to remove residual air bubbles. After molding, the internal porosity of the blank is 15.3%, and the pores are a uniform closed-cell structure. The product was then placed in an atmospheric pressure curing chamber for 18 hours of static curing. After demolding, it was placed in a steam curing kiln and heated to 80°C at a rate of 10°C / h. The relative humidity of the curing environment was maintained at 95%. After steam curing for 36 hours, it was cooled to room temperature at a rate of 8°C / h. After removal, it was placed in a room temperature storage area for natural storage for 7 days. Visual inspection showed no cracks or deformation, thus obtaining the reinforced environmentally friendly lightweight partition wall panel.

[0038] This embodiment addresses the shortcomings of high cost and low utilization rate of virgin aggregates by using composite recycled solid waste aggregates, solves the problem of low strength and easy cracking by forming a three-dimensional reinforcement network with composite fibers of varying lengths, and solves the problems of poor interfacial bonding and fiber agglomeration by using modified desulfurized gypsum and precise mixing parameters.

[0039] Example 3 The raw materials used to prepare the reinforced environmentally friendly lightweight partition wall panel in this embodiment are as follows by weight: 32 parts cementitious material, 38 parts composite recycled lightweight aggregate, 5 parts composite fiber reinforcing component, 3 parts modifier, and 14 parts deionized water. The cementitious material is a homogeneous mixture obtained by mixing 42.5 grade sulfoaluminate cement, 1250 mesh metakaolin, and silica fume with a silica content of 92 wt% in a mass ratio of 5:2:1. Before mixing, the moisture content of the three raw materials is 0.32 wt%. The mixing speed is 300 r / min, the mixing time is 4 min, and the mixing uniformity is 98.6%.

[0040] The composite recycled lightweight aggregate is a homogeneous aggregate obtained by mixing recycled polystyrene particles and modified desulfurized gypsum slag at a mass ratio of 1:4, with a bulk density of 350 kg / m³ and a single particle size range of 0.15-2.9 mm; the recycled polystyrene particles are homogeneous particles obtained by crushing, screening, and removing impurities from waste polystyrene insulation boards, with a single particle size of 0.1-2 mm and a bulk density of 102 kg / m³. The modified desulfurized gypsum slag is a solid waste desulfurized gypsum slag from thermal power plant that has been modified with a silane coupling agent. The pretreatment steps are as follows: the desulfurized gypsum slag is calcined at 150℃ for 2 hours to remove the water of crystallization, cooled, crushed and screened to a particle size of 0.5-3 mm, soaked in a 1.5 wt% KH550 silane coupling agent ethanol solution for 30 minutes with continuous stirring during the soaking process, filtered, and then dried in a 105℃ forced-air drying oven to constant weight. After cooling, the modified desulfurized gypsum slag is obtained, and its interfacial bonding strength with the cement matrix is ​​1.28 MPa.

[0041] The composite fiber reinforcement component is a homogeneous fiber mixture obtained by mixing basalt short chopped fibers with a length of 9 mm and a single filament diameter of 14 μm with polyacrylonitrile fibers with a length of 5 mm and a single filament diameter of 11 μm at a mass ratio of 2:1.5. Both types of fibers are treated with antistatic agents before mixing. After mixing, the fiber dispersion is 96.1%, and the tensile strength of each single filament is not less than 515 MPa.

[0042] The modified additive is a homogeneous mixture obtained by mixing polycarboxylate superplasticizer with a water reduction rate of 30%, calcium stearate foaming regulator with a mesh size of 200, sodium citrate retarder with a purity of 98.5wt%, and KH550 silane coupling agent in a mass ratio of 3:2:1:1. The effective component content is 97.8% before use.

[0043] The preparation steps in this embodiment are as follows: S1. Accurately weigh all raw material components according to the above weight proportions. First, put the pre-dried cementitious material and composite recycled lightweight aggregate into a vertical mixing kettle with a forced stirring structure. Stir at 350r / min for 4 minutes at room temperature and pressure. Simultaneously, perform 20kHz ultrasonic dispersion treatment during the stirring process to obtain a first mixture without stratification or agglomeration.

[0044] S2. Evenly sprinkle the composite fiber reinforcing component and modifying agent into the first mixture in the mixing vessel, increase the stirring speed to 520 r / min and continue stirring for 8 min. During the stirring process, add all the metered deionized water at a constant rate of 1.5 L / min. After the water is added, continue stirring for 2 min. Check the fiber dispersion every 2 min throughout the process. There is no fiber agglomeration or clumping. Finally, the second mixture with a flowability of 200 mm and a fiber dispersion of 96.0% is obtained.

[0045] S3. The second mixture is uniformly injected into a steel partition wall mold of 2440mm×610mm×90mm, and placed on a vibration table for vibration molding. The vibration frequency is 55Hz, the amplitude is 1.0mm, and the vibration time is 3min. During the vibration process, the mixture on the surface of the mold is scraped flat every 30s to remove residual air bubbles. After molding, the internal porosity of the blank is 18.2%, and the pores are a uniform closed-cell structure. The product was then placed in an atmospheric pressure curing chamber for 15 hours of static curing. After demolding, it was placed in a steam curing kiln and heated to 70°C at a rate of 10°C / h. The relative humidity of the curing environment was maintained at 93%. After steam curing for 30 hours, it was cooled to room temperature at a rate of 8°C / h. After removal, it was placed in a room temperature storage area for natural storage for 7 days. Visual inspection showed no cracks or deformation, thus obtaining the reinforced environmentally friendly lightweight partition wall panel.

[0046] This embodiment addresses the shortcomings of high cost and low utilization rate of virgin aggregates by using composite recycled solid waste aggregates, solves the problem of low strength and easy cracking by forming a three-dimensional reinforcement network with composite fibers of varying lengths, and solves the problems of poor interfacial bonding and fiber agglomeration by using modified desulfurized gypsum and precise mixing parameters.

[0047] Comparative Example This comparative example uses the existing conventional lightweight partition board formula and process. The raw materials by weight are: 35 parts of 42.5 grade ordinary Portland cement, 40 parts of virgin perlite aggregate, 2 parts of naphthalene-based water-reducing agent, and 16 parts of tap water. No composite recycled aggregate, composite fiber reinforcing components, or modifying additives are added. The preparation steps of this comparative example are as follows: Weigh the raw materials according to the weight parts, add the cement and perlite into the mixing tank and stir for 3 minutes, add the water-reducing agent and water and continue stirring for 5 minutes to obtain the mixture, pour it into the mold and vibrate it for 2 minutes, let it stand at room temperature for 24 hours to demold, and let it cure naturally for 28 days to obtain the finished ordinary lightweight partition board.

[0048] Table 1. Raw material composition and core parameters for each embodiment and comparative example. This table clarifies the differences in the raw material systems of each embodiment and the comparative example. All embodiments use the raw material composition and parameters defined by this invention, covering the entire value range of this invention. The comparative examples use conventional raw material systems of the prior art, without recycled solid waste or composite functional components, providing a clear variable basis for performance comparison.

[0049] Table 2. Performance test results of each embodiment and comparative example. The performance test results in this table show that the flexural strength and compressive strength of the three embodiments are more than 80% higher than those of the comparative example, the water absorption rate is reduced by more than 60%, the drying shrinkage value is reduced by more than 50%, and the solid waste utilization rate can reach up to 46%. All performance indicators are better than the requirements of national standards. The comparative example did not use modified desulfurized gypsum, composite fiber reinforcement, and precise curing process, and has the defects of low strength, high water absorption, large shrinkage, and no solid waste disposal capacity. These defects correspond completely to the defects of the prior art, fully verifying the effectiveness of the technical solution of this invention.

[0050] To address the shortcomings of high virgin aggregate consumption, low solid waste utilization rate, and high cost: all three embodiments of this invention use a composite recycled lightweight aggregate of recycled polystyrene particles and modified desulfurized gypsum slag, which 100% replaces the commonly used virgin perlite, ceramsite, and other natural aggregates in existing technologies. The solid waste utilization rate can reach up to 46%, directly reducing raw material procurement costs by more than 30%. At the same time, it realizes the high-value disposal of two types of solid waste: thermal power plant desulfurization gypsum and waste polystyrene board, which fully complies with the policy requirements for the low-carbon and circular development of building materials.

[0051] To address the shortcomings of insufficient mechanical properties and susceptibility to cracking and breakage, this invention employs a composite reinforcement system of basalt short-cut fibers and polyacrylonitrile fibers in combination with varying lengths. This system forms a three-dimensional interwoven network structure within the cement hydration matrix. The minimum flexural strength in the three embodiments is 3.6 MPa, an 80% improvement compared to the comparative example. The minimum impact resistance is improved by 1.4 times, and the drying shrinkage value is controlled below 0.42 mm / m. This completely avoids cracking, breakage, and corner chipping problems that occur during the installation and use of partition walls, significantly extending the product's service life.

[0052] To address the shortcomings of poor interfacial bonding between aggregates and cementitious matrix, high water absorption, and insufficient durability, this invention modifies the surface of desulfurized gypsum slag using a silane coupling agent. Through interfacial grafting reaction, active amino groups that can combine with cement hydration products are introduced onto the gypsum surface, increasing the interfacial bonding strength between aggregates and matrix by more than 30%. At the same time, the hydrophilicity of the gypsum surface is reduced. The water absorption rate of the three embodiments is less than 10%, which is more than 60% lower than that of the comparative example. It can withstand long-term water immersion without powdering or strength reduction, and its durability is more than double that of the existing technology.

[0053] To address the shortcomings of easy fiber agglomeration and poor product uniformity during the preparation process, the present invention adopts a combination of fiber antistatic pretreatment, step-by-step feeding and stirring, uniform water addition, and ultrasonic-assisted dispersion. The fiber dispersion degree of the three embodiments is higher than 95%, the performance deviation rate of the same batch of products is less than 3%, there is no local stress concentration defect, ensuring the performance uniformity of batch products and avoiding the problems of insufficient local strength and cracking caused by fiber agglomeration in the prior art.

[0054] The interfacial reactions involved in the modification process are as follows: NH2CH2CH2CH2Si(OCH3)3 + 3H2O → NH2CH2CH2CH2Si(OH)3 + 3CH3OH; The condensation of silanol groups with the hydroxyl groups on the surface of desulfurized gypsum: Si(OH)3 + nHO-CaSO4·0.5H2O → Si(O-CaSO4·0.5H2O) n (OH) 3-n +nH2O; The above reaction grafts silane molecules with amino active groups onto the surface of desulfurized gypsum. The amino groups can form chemical bonds with the calcium silicate gel generated by cement hydration, which greatly improves the interfacial bonding strength between desulfurized gypsum and cementitious matrix, while reducing the hydrophilicity of gypsum surface. This effectively solves the defects of unmodified desulfurized gypsum, such as weak bonding force with matrix and easy water absorption and powdering.

[0055] Reference Figure 2 This diagram compares the advantages and disadvantages based on measured mechanical data. Traditional comparative examples lack composite fibers and modified aggregates, and lack a three-dimensional bonding network, resulting in flexural and compressive strengths of only 2.0 MPa and 3.1 MPa, respectively, making them extremely prone to damage and cracking during transportation and installation. This invention uses a mixture of long and short basalt and polyacrylonitrile composite fibers, interwoven within the board to form a three-dimensional load-bearing skeleton. Combined with silane-modified desulfurized gypsum to enhance interfacial bonding, the three sets of results show a minimum flexural strength of 3.6 MPa and a compressive strength of 5.2 MPa, representing an improvement of over 80% compared to conventional products. Example 2, with the highest fiber content, exhibits the best mechanical properties, verifying the synergistic reinforcement effect of composite fibers and aggregate modification on strength enhancement, making it suitable for high-load partition wall applications. Reference Figure 3 Data shows that ordinary partition wall panels made of unmodified gypsum are highly hydrophilic, with a water absorption rate as high as 22.3%, making them extremely prone to absorbing water and turning into powder in humid kitchen and bathroom environments. This invention utilizes KH550 silane coupling agent to graft hydrophobic groups onto the surface of desulfurized gypsum, significantly reducing the hydrophilic properties of the aggregate. The water absorption rate of all three product groups is controlled below 10%, a reduction of over 60%. The bulk density varies with the proportion of recycled aggregate; Example 2 has a higher proportion of gypsum and a higher density, but still maintains its lightweight properties, combining the advantages of lightweight and water resistance and durability. It can be directly used for damp partition walls in kitchens and bathrooms, saving on additional waterproofing construction costs.

[0056] Reference Figure 4 Traditional formulas use only natural perlite aggregate, resulting in zero solid waste utilization, high mineral consumption, and high raw material costs. This invention completely replaces virgin aggregate with waste polystyrene particles and modified desulfurization gypsum, achieving industrial solid waste resource utilization. The solid waste utilization rates in the three embodiments range from 39.2% to 45.8%, with Embodiment 2 showing the highest aggregate addition ratio and optimal solid waste utilization. This approach not only utilizes desulfurization waste residue from thermal power plants and waste insulation plastics, aligning with low-carbon building materials policies, but also significantly reduces natural mineral procurement costs, achieving a win-win situation for environmental protection and production costs from the raw material perspective, facilitating industrial-scale production and promotion.

[0057] Reference Figure 5Conventional processes often involve fibers without antistatic pretreatment and with crude mixing methods, resulting in severe fiber agglomeration and a dispersion of only 72.1%. This leads to numerous open holes in the green body and a porosity as high as 26.7%, making the boards prone to water absorption, shrinkage, and deformation. This invention addresses this by pre-treating the raw materials with antistatic agents, combined with step-by-step feeding, ultrasonic dispersion, and segmented, controlled-speed water addition. This ensures a stable fiber dispersion of over 95.5%, with fibers uniformly interwoven to form a complete skeleton. Furthermore, precise vibration defoaming optimizes the pore structure into a uniform closed-cell structure, reducing the porosity to 15.3-21.2. This reduces water absorption channels, improving water resistance, and optimizes the sound insulation and lightweight properties of the board through closed pores, significantly improving batch-to-batch stability.

[0058] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A reinforced environment-friendly light-weight partition board, characterized in that, It is made from the following raw material components in parts by weight: 25-40 parts of cementitious material, 30-45 parts of composite recycled lightweight aggregate, 2-8 parts of composite fiber reinforcing component, 1-5 parts of modifying agent, and 10-18 parts of water; wherein the composite recycled lightweight aggregate is a mixture of recycled polystyrene particles and modified desulfurized gypsum slag, and the composite fiber reinforcing component is a mixture of basalt short-cut fibers and polyacrylonitrile fibers.

2. The reinforced environment-friendly light-weight partition wall board according to claim 1, characterized in that, The cementing material is a homogeneous mixture of sulfoaluminate cement, metakaolin, and silica fume in a mass ratio of 5:2:

1.

3. The reinforced environment-friendly light-weight partition wall board according to claim 1, characterized in that, The mass ratio of recycled polystyrene particles to modified desulfurized gypsum slag in the composite recycled lightweight aggregate is 1:3-5. The modified desulfurized gypsum slag is industrial solid waste desulfurized gypsum slag that has undergone surface modification treatment with a silane coupling agent.

4. The reinforced environment-friendly light-weight partition wall board according to claim 1, characterized in that, The composite fiber reinforcement component contains basalt short-cut fibers with a length of 6-12 mm and polyacrylonitrile fibers with a length of 3-8 mm, with a mass ratio of 2:1-2.

5. The reinforced environmentally friendly lightweight partition wall panel according to claim 1, characterized in that, The modified additive is a homogeneous mixture obtained by mixing polycarboxylate superplasticizer, calcium stearate foaming regulator, sodium citrate retarder, and KH550 silane coupling agent in a mass ratio of 3:2:1:

1.

6. A method for preparing a reinforced environmentally friendly lightweight partition wall panel, used to prepare the reinforced environmentally friendly lightweight partition wall panel according to any one of claims 1-5, characterized in that, Includes the following steps: S1. Weigh all raw material components according to the weight parts. First, put the cementitious material and composite recycled lightweight aggregate into the mixing tank and stir at room temperature for 3-5 minutes to obtain the first mixture. S2. Add composite fiber reinforcing components and modifying agents to the first mixture, and continue stirring for 6-10 minutes. During the stirring process, add all the water at a uniform rate to finally obtain a second mixture with a flowability of 180-220 mm. S3. Inject the second mixture into a mold of the corresponding specifications, vibrate to form, and then let it stand under normal pressure for 12-18 hours. After demolding, steam curing is carried out for 24-36 hours, and then it is naturally aged for 7 days to obtain a reinforced environmentally friendly lightweight partition board.

7. The method for preparing the reinforced environmentally friendly lightweight partition wall panel according to claim 6, characterized in that, The pretreatment steps for the modified desulfurized gypsum slag in S1 are as follows: the industrial solid waste desulfurized gypsum slag is crushed and screened to a particle size of 0.5-3 mm, soaked in a 1.5 wt% silane coupling agent ethanol solution for 30 min, filtered, and then dried at 105 ℃ to constant weight to obtain the modified desulfurized gypsum slag.

8. The method for preparing the reinforced environmentally friendly lightweight partition wall panel according to claim 6, characterized in that, The stirring speed in S2 is controlled at 450-600 r / min, and the water addition rate is controlled at 1.2-1.8 L / min. Fiber agglomeration and clumping are avoided throughout the stirring process.

9. The method for preparing the reinforced environmentally friendly lightweight partition wall panel according to claim 6, characterized in that, The vibration molding parameters in S3 are: vibration frequency of 50-60Hz, vibration time of 2-4min, and removal of residual air bubbles inside the mixture during vibration.

10. The method for preparing the reinforced environmentally friendly lightweight partition wall panel according to claim 6, characterized in that, The steam curing parameters in S3 are as follows: the steam curing temperature is controlled at 60-80℃, the relative humidity of the curing environment is maintained at above 90%, and the temperature rises and falls are avoided throughout the curing process.

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