Phosphogypsum-based fireproof decorative plate and application thereof

Abstract

The ardealite-based fireproof decorative plate is prepared from the following components in parts by weight: 40-60 parts of modified ardealite, 15-25 parts of white cement or Portland cement, 5-15 parts of a flame retardant, 3-8 parts of glass fibers or basalt fibers and 5-10 parts of a composite adhesive, the decorative plate can further comprise 5-10 parts of coal ash or slag powder. Specifically, the ardealite-based fireproof decorative plate is prepared through a compression molding process, and the decorative plate has good fireproof performance, mechanical strength and dimensional stability and meanwhile has the advantages of being environmentally friendly, capable of being produced on a large scale, low in cost and the like. Tests show that the decorative plate reaches the A-level non-combustible standard and is suitable for building spaces such as indoor wall surfaces, suspended ceilings and partitions. According to the invention, efficient utilization of ardealite resources is realized, and an effective way is provided for developing novel green fireproof building materials.

Description

Technical Field

[0001] The present invention belongs to the technical field of industrial solid waste resource utilization and building material preparation, and specifically relates to a low-cost, environmentally friendly fireproof decorative board prepared with phosphogypsum as the main raw material. Background Art

[0002] With the continuous improvement of green building and safety standards, building decoration materials must not only possess excellent mechanical properties and decorative effects, but also meet comprehensive performance requirements such as fire safety, environmental protection and energy conservation. Although traditional decorative panels such as gypsum board and calcium silicate board are widely used, they still have certain limitations in terms of raw material cost, resource dependence, fire resistance and environmental friendliness.

[0003] Phosphogypsum is a byproduct of phosphate fertilizer production, with a huge annual output. However, due to its impurities, moisture absorption, and mild radioactivity, its resource utilization rate has been low. Studies have attempted to use phosphogypsum in building materials, but most products suffer from low strength, poor durability, or unstable fire resistance, making it difficult to meet the comprehensive demand for high-performance decorative materials in modern architecture. Therefore, it is necessary to develop decorative panels made from phosphogypsum and other auxiliary materials that combine fire resistance, mechanical properties, and environmental performance to improve the resource utilization of phosphogypsum while meeting the functional needs of the construction industry. Summary of the Invention

[0004] The present invention provides a low-cost, environmentally friendly phosphogypsum-based fireproof decorative board, which solves the problems of insufficient mechanical properties, low fire resistance, and poor water resistance of existing phosphogypsum materials used in building decoration, and realizes the efficient utilization of phosphogypsum resources.

[0005] The phosphogypsum-based fireproof decorative board is prepared from the following components in parts by weight: 40-60 parts of phosphogypsum, 15-25 parts of white cement or Portland cement, 5-15 parts of flame retardant, 3-8 parts of glass fiber or basalt fiber, and 5-10 parts of composite adhesive.

[0006] Alternatively, it is made from the following components in parts by weight: 40-60 parts of phosphogypsum, 15-25 parts of white cement or silicate cement, 5-15 parts of flame retardant, 3-8 parts of glass fiber or basalt fiber, 5-10 parts of composite adhesive, and 5-10 parts of fly ash or slag powder (to improve the crack resistance and shrinkage stability of the board).

[0007] The phosphogypsum is a by-product of the wet phosphoric acid process, which is dried at low temperature (35-45°C) to a moisture content of less than 10%, and then crushed to a particle size of less than 100 mesh. The thickness of the decorative board is 8-15mm, and the dry density is 1.0-1.4 g / cm 3The flame retardant is aluminum hydroxide or magnesium hydroxide; the adhesive is polyvinyl alcohol-starch composite adhesive (the mass ratio of polyvinyl alcohol to starch is 2:1) or polyacrylate.

[0008] The specific preparation of the above-mentioned phosphogypsum-based fireproof decorative board is as follows: 1. Weighing and mixing of raw materials The above components are weighed in sequence according to the preset ratio. After mixing, water is added and mechanically stirred using a forced stirring device. The stirring time is controlled within 10-20 minutes to ensure that all components are mixed evenly. Special attention is paid to the dispersion of the flame retardant and the fiber to prevent the formation of local agglomeration that affects the performance of the later board. 2. Mold forming Pour the evenly mixed slurry into a pre-prepared standard flat plate mold, use a vibration or compaction device to remove large bubbles to make the plate structure denser. The mold material can be polyethylene or steel. The molding size is set according to demand, and the recommended thickness range is 8-15mm; 3. Drying and maintenance The initially set sheet, along with the mold, is placed in a low-temperature drying oven and cured at 60-80°C for 12-24 hours to complete hardening and moisture control. This temperature range accelerates hydration reaction, improves early strength, and effectively reduces the formation of shrinkage cracks. After this stage is completed, the finished sheet is produced. 4. Surface treatment and lamination (optional) After drying and curing, the board is demoulded and can be subjected to different types of finishing treatments depending on the product application.

[0009] Physical finishing: sanding, edging; Decorative lamination: PVC film, melamine paper, inorganic coating, etc. are selected for hot pressing or spraying to enhance the aesthetics, moisture resistance and stain resistance; Functional treatment: Add anti-mildew and anti-static coating.

[0010] Advantages and technical effects of the present invention: The decorative panels of the present invention utilize phosphogypsum as the primary binder, supplemented with cement, inorganic flame retardants, reinforcing fibers, and composite adhesives, manufactured through a rationally proportioned and compression-molded process. These panels exhibit excellent fire resistance, mechanical strength, and dimensional stability, while also being environmentally friendly, scalable, and cost-effective. Testing has shown that these decorative panels meet Class A non-combustibility standards and are suitable for use in indoor walls, ceilings, partitions, and other building spaces. This invention achieves efficient utilization of phosphogypsum resources and provides an effective approach for developing new, green, fire-resistant building materials. DETAILED DESCRIPTION

[0011] The present invention will be further described below with reference to the examples. However, the scope of the present invention is not limited to the following examples. Those skilled in the art will appreciate that various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. The instruments, reagents, and materials involved in the following examples, unless otherwise specified, are all conventional instruments, reagents, and materials already available in the prior art and can be obtained through regular commercial channels. The experimental methods, detection methods, etc. involved in the following examples, unless otherwise specified, are all conventional experimental methods and detection methods already available in the prior art; Example 1: Preparation of standard fireproof decorative panels The phosphogypsum-based fireproof decorative board of this embodiment is prepared from the following components in parts by weight: 50 parts of phosphogypsum (dried at 40°C, with a moisture content of 5%, crushed, and a particle size of ≤100 mesh), 20 parts of white cement, 10 parts of aluminum hydroxide, 5 parts of glass fiber (6 mm chopped), 8 parts of polyvinyl alcohol-starch composite adhesive, and 5 parts of fly ash; the liquid-to-solid ratio (g:mL) is 0.5:1. The above components were weighed and mixed in proportion, and then water was added at a liquid-solid ratio of g:mL=0.5:1. The mixture was stirred in a forced stirring device for 15 minutes until the mixture was uniformly mixed to form a slurry with good fluidity. The mixture was poured into a standard mold (dimensions of 300 mm×300 mm×12 mm) and compacted by vibration at a vibration frequency of 3000 times / min for 60 seconds. The mold and the board were placed in a drying oven and dried and cured at a constant temperature of 70°C for 18 hours. After demolding, the board was trimmed and the surface was coated with an inorganic mineral coating to obtain a decorative board. The decorative board of this embodiment has been tested to have a flexural strength (28 days) of 9.3 MPa, a thermal conductivity of 0.19 W / (m·K), and a fire performance grade of Class A non-combustible (GB 8624-2012). It also has good dimensional stability and a water absorption rate of less than 13%.

[0012] Example 2: Preparation of film-coated fireproof decorative panels The preparation method of the decorative board of this embodiment is the same as that of embodiment 1, except that the surface of the decorative board after curing is subjected to PVC coating treatment to enhance its decorativeness, anti-fouling property and durability.

[0013] The lamination process steps are as follows: Sand the surface of the cured and dried board to remove dust and burrs to ensure the adhesion of the film; select a flame-retardant PVC film (thickness of about 0.2mm) and cut the film material according to the size of the board; use hot-pressing laminating equipment to attach the film material to the front of the board, control the film temperature at 110-130℃, press for 20-30s, and use static pressure or roller compaction; after natural cooling, trim the edges and shape to complete the product.

[0014] Product performance evaluation: The finish is firmly bonded, with no delamination, bubbling, or edge warping. Tested according to GB / T 17657, the scratch resistance rating is above Level 4, meeting interior decoration requirements. The decorative effect is beautiful and uniform, and can be customized with a variety of wood grain, stone, and solid color patterns. It is suitable for public buildings such as hospitals, schools, and office buildings.

[0015] Example 3: Preparation of thin fireproof ceiling panels In order to meet the demand of modern buildings for lightweight ceiling systems, the preparation method of the decorative board in this embodiment is the same as that in Example 1, except that the forming mold and pressing process are adjusted to prepare a lightweight fireproof board with a thickness of only 8 mm; the vibration compaction strength is slightly reduced to 2000 times / min, and the vibration time is 30 seconds to reduce the density but maintain a uniform structure; the surface of the board is lightly frosted and no lamination process is used to maintain the fireproof properties of the original board.

[0016] The properties of the finished board are tested as follows: the dry density of the board is 1.05 g / cm 3 Flexural strength (28 days): ≥8 MPa; thermal conductivity: 0.18 W / (m·K); fire rating: Class A, non-combustible; can be nailed, sawed, and drilled, and is compatible with keel hoisting systems; The length / width dimensions can be customized to standard module sizes such as 600×600 mm and 1200×600 mm.

[0017] Typical application scenarios: It is suitable for large-area suspended ceiling areas such as office spaces, school classrooms, hospital clinics, shopping mall public areas, etc., and has the characteristics of being lightweight, fireproof, and easy to construct.

Claims

1. A phosphogypsum-based fireproof decorative board, characterized in that: The invention is prepared from the following components in parts by weight: 40-60 parts of phosphogypsum, 15-25 parts of white cement or silicate cement, 5-15 parts of flame retardant, 3-8 parts of glass fiber or basalt fiber, and 5-10 parts of composite adhesive.

2. A phosphogypsum-based fireproof decorative board, characterized in that: The invention is prepared from the following components in parts by weight: 40-60 parts of modified phosphogypsum, 15-25 parts of white cement or silicate cement, 5-15 parts of flame retardant, 3-8 parts of glass fiber or basalt fiber, 5-10 parts of composite adhesive, and 5-10 parts of fly ash or slag powder.

3. The phosphogypsum-based fireproof decorative board according to claim 1 or 2, characterized in that: Phosphogypsum is a by-product of the wet phosphoric acid process. It is dried at low temperature to a moisture content of less than 10% and then crushed to a particle size of less than 100 mesh.

4. The phosphogypsum-based fireproof decorative board according to claim 1, characterized in that: The thickness of the decorative board is 8-15mm, and the dry density is 1.0-1.4 g / cm 3 .

5. The phosphogypsum-based fireproof decorative board according to claim 1 or 2, characterized in that: The flame retardant is aluminum hydroxide or magnesium hydroxide, and the adhesive is polyvinyl alcohol-starch composite adhesive or polyacrylate.

6. The phosphogypsum-based fireproof decorative board according to claim 1 or 2, characterized in that: The components are mixed, water is added and stirred, and then injected into a mold and molded into a board. After the initial setting board is placed at 60-80° C. for curing for 12-24 hours, the surface is treated or coated to obtain a phosphogypsum-based fireproof decorative board.

7. The phosphogypsum-based fireproof decorative board according to claim 6, characterized in that: Lamination refers to covering a layer of inorganic mineral coating or PVC film to enhance its decorativeness, anti-fouling properties and durability.

8. Use of the phosphogypsum-based fireproof decorative board according to claim 1 or 2 in indoor wall surfaces, ceilings, and partition structures.