Porous board and method for manufacturing the same

Abstract

A porous board and its manufacturing method are disclosed. The method includes: a premixed slurry preparation step, in which silicon dioxide powder, magnesium sulfate, and water are mixed evenly; a modified slurry preparation step, in which the premixed slurry and magnesium sulfate modifier are mixed evenly; a foamed slurry preparation step, in which a foaming agent and water are mixed evenly, and then gas is introduced to generate foam inside; a surface layer preparation step, in which another premixed slurry, magnesium oxide, and another magnesium sulfate modifier are mixed evenly to form a surface layer, and a first fiber layer is laid; a first base layer stacking step, in which the modified slurry, magnesium oxide, plant fiber, and foamed slurry are mixed evenly, applied to the first fiber layer, and a second fiber layer is laid; a second base layer stacking step, in which the modified slurry, magnesium oxide, plant fiber, and foamed slurry are mixed evenly, applied to the second fiber layer, and a third fiber layer is laid; and an air-drying and settling step.

Claims

1. A method for manufacturing a porous plate, comprising: (1) Premixed slurry preparation step: Silicon dioxide powder, magnesium sulfate and water are mixed evenly to form a premixed slurry, wherein the magnesium sulfate is anhydrous magnesium sulfate or magnesium sulfate hydrate; (2) Modified slurry preparation step: The premixed slurry and magnesium sulfate modifier are mixed evenly to form a modified slurry; (3) Foamed slurry preparation step: Foaming agent and water are mixed evenly to form a slurry to be foamed, and then gas is introduced into the slurry to be foamed to generate foam inside, thereby forming a foamed slurry; (4) Surface layer preparation step: Another portion of the premixed slurry, magnesium oxide and another portion of the magnesium sulfate modifier are mixed evenly to form a surface layer slurry, a surface layer is made using the surface layer slurry, and a first fiber layer is laid on the surface layer; (5) (6) First base layer stacking step: uniformly mix the modified mud, magnesium oxide, fiber and foamed slurry to form a first base slurry, apply the first base slurry to the first fiber layer to form a first base layer, and lay a second fiber layer on the first base layer; (7) Second base layer stacking step: uniformly mix another of the modified mud, magnesium oxide, fiber and another of the foamed slurry to form a second base slurry, apply the second base slurry to the second fiber layer to form a second base layer, and lay a third fiber layer on the second base layer; and (8) Air drying and settling step: air dry and settling the multilayer structure obtained by the second base layer stacking step until it is completely hardened, thereby producing the porous board.

2. A method for manufacturing a porous plate as described in claim 1, wherein, In the premixed slurry preparation step, the silicon dioxide powder, magnesium sulfate, and water are mixed uniformly at a weight ratio of 33~47:19~58:24~37; in the modified slurry preparation step, the premixed slurry and the magnesium sulfate modifier are mixed uniformly at a weight ratio of 85~110:0.0095~2.6; in the foamed slurry preparation step, the foaming agent and water are mixed uniformly at a weight ratio of 2~32:81~100; in the surface layer preparation step, the additional premixed slurry, magnesium oxide, and the additional magnesium sulfate modifier are mixed uniformly at a weight ratio of 66~84:18~32:0.0095~0.

63. In the first base layer stacking step, the modified mud, the magnesium oxide, the fiber, and the foamed slurry are mixed uniformly in a weight ratio of 52~68:7~32:9~16:0.0095~2.1; and in the second base layer stacking step, the modified mud, the magnesium oxide, the fiber, and the foamed slurry are mixed uniformly in a weight ratio of 52~68:7~32:9~16:0.0095~2.

1.

3. A method for manufacturing a porous plate as described in claim 1, wherein, The first fiber layer includes at least one layer of nonwoven fabric and at least one layer of fiberglass cloth, arranged sequentially from the side adjacent to the surface layer to the side adjacent to the first base layer; the second fiber layer includes at least one layer of fiberglass cloth; and the third fiber layer includes at least one layer of fiberglass cloth and at least one layer of nonwoven fabric, arranged sequentially from the side adjacent to the second base layer.

4. A method for manufacturing a porous plate as described in claim 1, wherein, The thickness of the wet coating on the surface layer is 0.85~1 mm, the thickness of the wet coating on the first base layer is 5.5~6.5 mm, and the thickness of the wet coating on the second base layer is 4.5~5.5 mm.

5. A method for manufacturing a porous plate as described in claim 1, wherein, The silica powder is a powder recovered from stone grinding, and the average particle size of the silica powder is defined by a sieve with a mesh size of 48 or larger.

6. A method for manufacturing a porous plate as described in claim 1, wherein, The fiber has an average particle size defined by a sieve of 10 mesh or larger and a moisture content of less than 15 wt%.

7. A method for manufacturing a porous plate as described in claim 1, wherein, The magnesium sulfate modifier contains at least one selected from the group consisting of phosphates, borates, and citric acid.

8. A method for manufacturing a porous plate as described in claim 1, wherein, The foaming agent contains at least one selected from the group consisting of sodium dodecyl sulfate (SDS) and polyvinyl alcohol (PVA).

9. A method for manufacturing a porous plate as described in claim 1, wherein, The fiber comprises at least one selected from the group consisting of wood chips, bagasse fiber, hemp fiber, carbon fiber, and glass fiber.

10. A porous sheet material produced by the manufacturing method described in any one of claims 1 to 9.

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