A calcium sulfate decorative panel and a method of making the same

Abstract

The application discloses a calcium sulfate decorative panel and a preparation method thereof. The calcium sulfate decorative panel comprises a base and a surface layer on the upper surface of the base. The base is composed of high-strength composite material layers and adhesive layers arranged in an alternating stack. The bottom layer of the base is a high-strength composite material layer, and the top layer is an adhesive layer. A fiber mesh layer is arranged between any adjacent high-strength composite material layer and adhesive layer. The surface layer is a decorative veneer or a high-strength composite material layer subjected to surface mechanical processing. The preparation raw material of the high-strength composite material layer comprises high-strength gypsum powder, cement, silica fume, starch, quartz powder, reinforcing fiber, water and a dispersing agent. Compared with traditional decorative panel materials, the base structure is more stable and solid through the stack processing, the surface layer processing capacity is better, the base material has high plasticity, and the market design and batch production conditions can be achieved through certain process organization optimization.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of new building materials, and particularly relates to a calcium sulfate decorative panel and a preparation method thereof. BACKGROUND

[0002] In recent years, outdoor building structures and indoor and outdoor design projects are in the ascendant. As one of the most commonly used materials in the industry, the use of calcium sulfate products has increased rapidly, and at the same time, multifunctional, multi-category and multi-design development space materials are needed to meet market demand and provide new vitality to the market.

[0003] Traditional calcium sulfate panel base materials commonly use sodium sulfate and calcium chloride as reactants, prepare calcium sulfate by adding ethanol as a modifier, and are formed under normal pressure and hydrothermal conditions with additional latex and fibers. The panels formed by the traditional one-piece forming process generally have general overall strength, a large amount of water is used in the production of products, and the anti-cracking performance is low in secondary processing production, which is prone to cracking in secondary processing and causes local separation of the material. At the same time, there are great limitations in product secondary design and artistic processing space, and there are problems such as high mold opening cost in personalized custom production. Therefore, how to expand the development space while improving the stability of calcium sulfate base materials, improving the mechanical properties, optimizing the stability of engineering materials, and reducing the production and processing cost is the current research direction. SUMMARY

[0004] The present application aims to at least solve one of the technical problems existing in the prior art. To this end, the present application proposes a calcium sulfate decorative panel and a preparation method thereof.

[0005] According to one aspect of the present application, a calcium sulfate decorative panel is proposed, which comprises a base and a surface layer covering the upper surface of the base, the base is composed of high-strength composite material layers and adhesive layers arranged in an alternating stack, and the bottom layer of the base is the high-strength composite material layer and the top layer is the adhesive layer, a fiber mesh layer is provided between any adjacent high-strength composite material layer and adhesive layer, and the surface layer is a decorative veneer material or a high-strength composite material layer subjected to surface mechanical processing; the preparation raw materials of the high-strength composite material layer include high-strength gypsum powder, cement, silica fume, starch, quartz powder, reinforcing fibers, water and a dispersing agent; and the main preparation raw material of the adhesive layer is a water-based epoxy resin emulsion.

[0006] In some embodiments of the present application, the preparation raw materials of the high-strength composite material layer are as follows in parts by mass: high-strength gypsum powder 20-50 parts, cement 1-3 parts, silica fume 1-5 parts, quartz powder 1-5 parts, reinforcing fibers 1-3 parts, water 1-15 parts, the amount of starch is 3-5% of the mass of high-strength gypsum powder, and the amount of dispersing agent is 0.03-0.08% of the mass of high-strength gypsum powder.

[0007] In some embodiments of the present application, the amount of the aqueous epoxy resin emulsion is 2-6% of the mass of the high-strength gypsum powder.

[0008] In some embodiments of the present application, the reinforcing fiber is at least one of pulp fiber, polymer fiber, steel fiber or carbon fiber.

[0009] In some embodiments of the present application, the material of the fiber web layer is one of polymer fiber, steel fiber or carbon fiber; and the processing method of the fiber web layer includes laying a single-layer continuous web-shaped fiber web or adding non-continuous web-shaped fiber material by spreading or embedding. The fiber network formed after the non-continuous web-shaped fiber material is laid can also improve the crack resistance and increase the toughness of the base.

[0010] In some embodiments of the present application, the dispersant is at least one of poly naphthalene formaldehyde sulfonic acid sodium salt, sodium pyrophosphate or sodium hexametaphosphate. The type of dispersant can be selected according to the actual production situation. Preferably, the dispersant is poly naphthalene formaldehyde sulfonic acid sodium salt.

[0011] In some embodiments of the present application, the epoxy equivalent weight of the epoxy resin in the aqueous epoxy resin emulsion is 490-520 g / eq, the viscosity of the aqueous epoxy resin emulsion is 400-750 CPS, and the emulsion particle size <1 μm accounts for more than 90%. Further, the aqueous epoxy resin emulsion is selected from epoxy resin GCC135 or epoxy resin F0707. The aqueous epoxy resin emulsion has good water solubility and is convenient for maintenance and storage in the production environment, and can also produce a self-adaptive balance adjustment effect of water in the material as a whole with the starch-gel produced by water and starch.

[0012] In some embodiments of the present application, the high-strength gypsum powder has a whiteness of 80 or more, a fineness of 220 mesh, a modulus of rupture of 6.5-7.0, and a standard consistency of 30-50%. Preferably, the standard consistency is 46-47%.

[0013] In some embodiments of the present application, the cement is Portland cement, has a fineness of 3.0-30.0 μm, a standard consistency of ≤28, and a strength grade of 32.5R.

[0014] In some embodiments of the present application, the silica ash has a SiO2purity of 94% or more, an average particle size of 0.1-0.3 μm, and a specific surface area of 20-28 m 2 / g.

[0015] In some embodiments of the present application, the quartz powder has a fineness of 120-180 mesh.

[0016] The application further provides a preparation method of the calcium sulfate decorative panel, raw materials of the high-strength composite layer are mixed, the obtained slurry is spread on the surface of a mold, and then pressure is applied to remove water to obtain a high-strength composite layer, the water-based epoxy resin emulsion is sprayed on the surface of the high-strength composite layer to form a bonding layer, and then the above-mentioned preparation process of the high-strength composite layer and the bonding layer is repeated, and the fiber web layer is laminated between any adjacent high-strength composite layer and bonding layer during the process, after the target number of layers is reached, the product is left to stand, demolded, and cured to complete the preparation of the base; when the surface layer is a decorative veneer, the decorative veneer is attached to the surface of the prepared base; when the surface layer is a high-strength composite layer subjected to surface mechanical processing, the high-strength composite layer is used as the top layer during the preparation of the base, and the high-strength composite layer is subjected to mechanical processing to form a relief pattern after the preparation of the base is completed.

[0017] In some embodiments of the application, the pressure for the pressure water removal is 1-1.5 MPa, and the time for the pressure water removal is 10-60 s.

[0018] In some embodiments of the application, the time for the standing is 30-40 h.

[0019] According to a preferred embodiment of the application, at least the following beneficial effects are achieved:

[0020] 1. The calcium sulfate decorative panel of the application has a more stable and solid internal structure compared with traditional decorative panel materials, and can avoid separation or cracking of the base during mechanical processing such as engraving and etching of the surface layer, thereby having better processing capacity of the surface layer; the preparation method of the stacked processing breaks the thickness limitation of the traditional calcium sulfate plate integrated molding, and does not cause cracking problem regardless of the thickness of the stacked base, and the increase in thickness gives the base better secondary development design potential; the stacked processing method can use a general mold without using a special mold for traditional calcium sulfate plate integrated molding, and has higher processing flexibility and lower production cost. In general, the decorative panel base material after the interlayer stacking treatment of the application can effectively improve the high-temperature stability and improve the crack resistance, which has great significance for improving the physical and chemical properties of the material and expanding the application field of the product. The base material has strong plasticity and can be mass-produced after market design and process organization optimization.

[0021] 2. The starch is accelerated to gelatinize under the action of calcium sulfate, and the starch gel can effectively bind the water diffusion in the calcium sulfate material, so that the water required for the main material forming is self-adaptive, avoiding the increase of water content in the final product, and also playing a role in controlling the stability of the gypsum forming effect. Under the premise of ensuring the cohesion and strength of the material, by controlling the water consumption in the production process and adjusting the calcium sulfate component ratio of the base material, the mass is reduced by about 15.6% under the condition of doubling the thickness.

[0022] 3. The base material of the calcium sulfate decorative panel is applied with poly naphthalene formaldehyde sodium sulfonate for dispersing slurry, water-based epoxy resin emulsion for enhancing interlayer bonding capacity and improving crack resistance, silica ash for enhancing the base main structure, reinforcing fibers for improving crack resistance and increasing the strength and toughness of the base, and fiber mesh layer and other materials, which comprehensively improves the strength, heat resistance, and external force resistance of the panel.

[0023] 4. The new functional decorative base material of the application is a product developed in response to the two trends of building energy saving and residential industrialization. Based on the excellent physical and chemical properties of the base material, it can customize one hundred different decorative effects. The product has strong impact resistance, ultraviolet resistance, color stability, alkali resistance, crack resistance, and good waterproof performance. The double fixing system of load-bearing type sticking and mechanical anchoring is used for fixing and installation, the overall tensile strength reaches more than 100kpa, has good wind load capacity and tensile resistance, and at the same time ensures the appearance effect. It is suitable for existing building energy saving reconstruction engineering, public building decoration engineering, and residential building energy saving engineering. DETAILED DESCRIPTION

[0024] The concept and technical effects of the application will be described below in combination with examples to fully understand the purpose, features and effects of the application. Obviously, the described examples are only part of the examples of the application, not all examples, and other examples obtained by those skilled in the art without creative labor based on the examples of the application are within the scope of protection of the application.

[0025] Example 1

[0026] A calcium sulfate decorative panel is prepared in this embodiment, from bottom to top, in order, a high-strength composite layer, a polypropylene fiber mesh layer, a bonding layer, a high-strength composite layer, a bonding layer, a high-strength composite layer, a bonding layer, and a surface layer which is a decorative veneer. The high-strength composite layer is prepared from the following raw materials (in parts by mass): high-strength gypsum powder 30 parts, Portland cement 2 parts, silica fume 2 parts, quartz powder 1 part, paper pulp fiber 3 parts, and water 15 parts. Starch and polyformaldehyde sulfonate sodium salt are also added, with the amount of starch being 3% of the mass of the high-strength gypsum powder, and the amount of polyformaldehyde sulfonate sodium salt being 0.05% of the mass of the high-strength gypsum powder. The main raw material for the bonding layer is GCC-135 water-based epoxy resin emulsion, with the amount being 2% of the mass of the high-strength gypsum powder. The high-strength gypsum powder has a whiteness of 80, a fineness of 220 mesh, a modulus of rupture of 7.0, and a standard consistency of 47%. The Portland cement has 95% concentrated in a fineness of 3.0-30.0 μm, a standard consistency of 28, and a strength grade of 32.5R. The silica fume has high activity, a purity of SiO2 of 98%, an average particle size of 0.2 μm, and a specific surface area of 26 m 2 / g. The quartz powder has an average fineness of 180 mesh.

[0027] The specific preparation process is as follows:

[0028] The raw materials for the high-strength composite layer are mixed, the obtained slurry is spread on the surface of a mold, and then water is removed by pressing, to complete the production of the first high-strength composite layer. The high-strength composite layer is pressed for 30 s under a pressure of 1.1 MPa, and a single layer of polypropylene fiber mesh is laid on the surface of the high-strength composite layer. Then, the water-based epoxy resin emulsion is sprayed on the surface of the high-strength composite layer to form a bonding layer. Then, the production process of the high-strength composite layer and the bonding layer is repeated until the target number of layers is reached (the top layer is a bonding layer). After that, the product is cured and shaped, and is horizontally placed for 36 hours before being demolded. The product is maintained, and the production of the base is completed. The decorative veneer is attached to the surface of the produced base, to obtain the calcium sulfate decorative panel.

[0029] The calcium sulfate decorative panel of this embodiment has a thickness of 120 mm, and has a compressive strength of 24.2 MPa and a tensile strength of 188.64 N when tested under GB / T 7019-2014.

[0030] Example 2

[0031] A calcium sulfate decorative panel is prepared in this embodiment, from bottom to top, in order, a high-strength composite layer, a polypropylene fiber mesh layer, a bonding layer, a high-strength composite layer, a bonding layer, a high-strength composite layer, a bonding layer, and a surface layer which is a decorative veneer. The high-strength composite layer is prepared from the following raw materials (in parts by mass): high-strength gypsum powder 30 parts, Portland cement 2 parts, silica fume 2 parts, quartz powder 1 part, paper pulp fiber 5 parts, and water 15 parts. Starch and polyformaldehyde sulfonate sodium salt are also added, with the amount of starch being 3% of the mass of the high-strength gypsum powder, and the amount of polyformaldehyde sulfonate sodium salt being 0.05% of the mass of the high-strength gypsum powder. The main raw material for the bonding layer is GCC-135 water-based epoxy resin emulsion, with the amount being 2% of the mass of the high-strength gypsum powder. The high-strength gypsum powder has a whiteness of 80, a fineness of 220 mesh, a modulus of rupture of 7.0, and a standard consistency of 47%. The Portland cement has 95% concentrated in a fineness of 3.0-30.0 μm, a standard consistency of 28, and a strength grade of 32.5R. The silica fume has high activity, a purity of SiO2 of 98%, an average particle size of 0.2 μm, and a specific surface area of 26 m 2 / g. The quartz powder has an average fineness of 180 mesh.

[0032] The specific preparation process is as follows:

[0033] The raw materials for the high-strength composite layer are mixed, the obtained slurry is spread on the surface of a mold, and then water is removed by pressing, to complete the production of the first high-strength composite layer. The high-strength composite layer is pressed for 30 s under a pressure of 1.1 MPa, and a single layer of polypropylene fiber mesh is laid on the surface of the high-strength composite layer. Then, the water-based epoxy resin emulsion is sprayed on the surface of the high-strength composite layer to form a bonding layer. Then, the production process of the high-strength composite layer and the bonding layer is repeated until the target number of layers is reached (the top layer is a bonding layer). After that, the product is cured and shaped, and is horizontally placed for 36 hours before being demolded. The product is maintained, and the production of the base is completed. The decorative veneer is attached to the surface of the produced base, to obtain the calcium sulfate decorative panel.

[0034] The calcium sulfate decorative panel of this embodiment has a thickness of 120 mm, and has a compressive strength of 27.2 MPa and a tensile strength of 203.82 N when tested under GB / T 7019-2014.

[0035] Example 3

[0036] A calcium sulfate decorative panel is prepared in this example, from bottom to top, in turn, high-strength composite layer, polypropylene fiber mesh layer, adhesive layer, high-strength composite layer, adhesive layer, high-strength composite layer, adhesive layer, surface layer, and the surface layer is a decorative veneer. The raw materials for preparing the high-strength composite layer are (by mass fraction): high-strength gypsum powder 30 parts, Portland cement 2 parts, silica fume 2 parts, quartz powder 1 part, paper pulp fiber 5 parts, and water 15 parts. Starch and polyformaldehyde sulfonate sodium salt are also added, the amount of starch is 3% of the mass of high-strength gypsum powder, and the amount of polyformaldehyde sulfonate sodium salt is 0.05% of the mass of high-strength gypsum powder. The main raw material for preparing the adhesive layer is GCC-135 water-based epoxy resin emulsion, and the amount is 3% of the mass of high-strength gypsum powder. The whiteness of high-strength gypsum powder is 80, the fineness is 220 mesh, the bending coefficient is 7.0, and the standard consistency is 47%. The Portland cement has a concentration of 95% with a fineness of 3.0-30.0 μm, a standard consistency of 28, and a strength grade of 32.5R. The silica fume has high activity, a SiO2 purity of 98%, an average particle size of 0.2 μm, and a specific surface area of 26 m 2 / g. The average fineness of the quartz powder is 180 mesh.

[0037] The specific preparation process is as follows:

[0038] The raw materials for preparing the high-strength composite layer are mixed, the obtained slurry is spread on the surface of the mold, and then water is removed by pressing, the first high-strength composite layer is completed, the pressure is 1.1 MPa, the pressure is 30 s, and a single layer of polypropylene fiber mesh layer is laid on the surface of the high-strength composite layer, then the water-based epoxy resin emulsion is sprayed on the surface of the high-strength composite layer to form an adhesive layer, and then the above-mentioned preparation process of the high-strength composite layer and the adhesive layer is repeated until the target number of layers is reached (the top layer is an adhesive layer), and then the curing is completed, the mold is removed after 36 hours of horizontal placement, and the base is completed. The decorative veneer is attached to the surface of the prepared base to obtain a calcium sulfate decorative panel.

[0039] The thickness of the calcium sulfate decorative panel of this example is 120 mm, and the compressive strength is 25.1 MPa and the tensile strength is 201.12 N when tested under GB / T 7019-2014.

[0040] Comparative Example 1

[0041] A gypsum board is prepared in this comparative example, and the specific process is as follows:

[0042] The high-strength gypsum powder 25 parts, Portland cement 2 parts, pulp fiber 5 parts, water 15 parts, starch 2 parts were mixed into a slurry, then added to a blender for stirring. The hemihydrate gypsum gradually converted to dihydrate gypsum through the hydration process. The slurry was poured into a mold, placed horizontally, and dried at 70°C for 12 hours. The gypsum board was then removed from the mold. The high-strength gypsum powder used in this comparative example had a whiteness of 80, a fineness of 220 mesh, a modulus of rupture of 7.0, and a standard consistency of 47%. The Portland cement had a fineness of 3.0-30.0 μm, a standard consistency of 28, and a strength grade of 32.5R.

[0043] The gypsum board of this comparative example had a thickness of 120 mm and a compressive strength of 13.7 MPa and a tensile strength of 93.43 N when tested according to GB / T 7019-2014.

[0044] The above embodiments of the present application have been described in detail, but the present application is not limited to the above embodiments. Various modifications can be made within the scope of knowledge of those skilled in the art without departing from the spirit of the present application. Furthermore, the embodiments of the present application and the features in the embodiments can be combined with each other without conflict.

Claims

1. A calcium sulfate decorative panel, characterized in that, The calcium sulfate decorative panel includes a substrate and a surface layer covering the upper surface of the substrate. The substrate is composed of alternating layers of high-strength composite material and an adhesive layer, with the high-strength composite material layer as the bottom layer and the adhesive layer as the top layer. A fiber mesh layer is provided between any adjacent high-strength composite material layer and adhesive layer. The surface layer is a decorative veneer material or a high-strength composite material layer that has undergone surface mechanical processing. The raw materials for preparing the high-strength composite material layer include high-strength gypsum powder, cement, silica fume, starch, quartz powder, reinforcing fibers, water, and dispersant. The main raw material for preparing the adhesive layer is an aqueous epoxy resin emulsion. The raw materials for preparing the high-strength composite material layer are as follows (by weight): 20-50 parts high-strength gypsum powder, 1-3 parts cement, 1-5 parts silica fume, 1-5 parts quartz powder, 1-3 parts reinforcing fiber, and 1-15 parts water; the amount of starch is 3-5% of the mass of the high-strength gypsum powder; and the amount of dispersant is 0.03-0.08% of the mass of the high-strength gypsum powder. The processing method of the fiber web layer includes laying a single-layer continuous network structure of fiber web or adding non-continuous network structure of fiber material by spreading or embedding.

2. The calcium sulfate decorative panel according to claim 1, characterized in that, The amount of the water-based epoxy resin emulsion used is 2-6% of the mass of the high-strength gypsum powder.

3. The calcium sulfate decorative panel according to claim 1, characterized in that, The reinforcing fiber is at least one of pulp fiber, polymer fiber, steel fiber, or carbon fiber.

4. The calcium sulfate decorative panel according to claim 1, characterized in that, The fiber web is made of one of the following materials: polymer fiber, steel fiber, or carbon fiber.

5. The calcium sulfate decorative panel according to claim 1, characterized in that, The epoxy equivalent of the epoxy resin in the aqueous epoxy resin emulsion is 490-520 g / equivalent, the viscosity of the aqueous epoxy resin emulsion is 400-750 CPS, and the emulsion particle size <1 μm accounts for more than 90%.

6. The calcium sulfate decorative panel according to claim 1, characterized in that, The high-strength gypsum powder has a whiteness of 80 or higher, a fineness of 220 mesh, a flexural strength of 6.5-7.0, and a standard consistency of 30-50%.

7. The calcium sulfate decorative panel according to claim 1, characterized in that, The cement is silicate cement with a fineness of 3.0-30.0 μm, a standard consistency of ≤28%, and a strength grade of 32.5 R.

8. The calcium sulfate decorative panel according to claim 1, characterized in that, The silica fume has a SiO2 purity of over 94%, an average particle size of 0.1-0.3 μm, and a specific surface area of ​​20-28 m². 2 / g.

9. The method for preparing a calcium sulfate decorative panel according to any one of claims 1-8, characterized in that, The raw materials for preparing the high-strength composite material layer are mixed, and the resulting slurry is spread on the surface of a mold. Then, it is pressurized and dehydrated to obtain the high-strength composite material layer. The water-based epoxy resin emulsion is sprayed onto the surface of the high-strength composite material layer to form an adhesive layer. The above-mentioned production processes for the high-strength composite material layer and adhesive layer are repeated. During this process, the fiber mesh layer is stacked between any adjacent high-strength composite material layers and adhesive layers. After reaching the target number of stacked layers, the layer is left to stand, demolded, and cured to complete the substrate production. When the surface layer is a decorative veneer material, the decorative veneer material is applied to the surface of the completed substrate. When the surface layer is a high-strength composite material layer that has undergone surface mechanical processing, the high-strength composite material layer is used as the top layer during substrate preparation. After completing the substrate production, the surface of the high-strength composite material layer is mechanically processed to form an embossed pattern.