Cuttable and splicable light-weight fireproof and tough plate and preparation method thereof

Abstract

This invention discloses a cutable and splicable lightweight fire-resistant and tough board and its preparation method. The cutable and splicable lightweight fire-resistant and tough board is composed of the following raw materials in parts by weight: 50-90 parts fly ash, 10-50 parts refractory filler, 5-20 parts organic adhesive, 2-15 parts reinforcing agent, 0.1-2 parts flame retardant, and 0.5-2 parts toughening agent. This invention uses high-temperature resistant fly ash and refractory filler as binding materials, and polyurethane, epoxy resin, and organosilicon polymers as adhesives. Appropriate amounts of structural reinforcing materials, flame retardants, and toughening agents are added, and the proportions of each component are optimized to prepare a cutable and splicable lightweight fire-resistant and tough multifunctional board. This board is lightweight, fireproof, waterproof, impact-resistant, and tough. It can be cut into different shapes according to needs, is flexible and mobile in use, has few limitations, and has good fire resistance, meeting the national standard A level. It has great market value and wide engineering applicability.

Description

Technical Field

[0001] This invention belongs to the field of building materials technology, specifically relating to a lightweight, fire-resistant, and tough board that can be cut and spliced, and its preparation method. Background Technology

[0002] With the rapid development of the construction industry, innovation in building materials has become particularly important. Especially in high-rise buildings and complex building structures, the performance requirements for materials are even more stringent. Modern high-rise and large-scale buildings require a large amount of engineering panels, which must be lightweight, high-strength, impact-resistant, and fire-resistant. In addition, for the needs of transportation, processing, and installation, they must be cut and directly assembled.

[0003] Currently, there are many types of engineering building materials used in China, among which light steel keel gypsum board, cement fiberboard, and foamed concrete board have relatively good overall performance. Light steel keel gypsum board has relatively low strength, poor water resistance, is unsuitable for humid environments, and has only average fire resistance; cement fiberboard is heavy, requires high-quality wall structures, and is relatively expensive; foamed concrete board has low strength, is brittle, has a high breakage rate during handling, and is difficult to cut and assemble freely. These limitations not only affect the safety performance of buildings but also restrict design flexibility and building sustainability.

[0004] To adapt to the trend of high-rise and large-scale buildings in my country, and to overcome the shortcomings of existing engineering panels in terms of quality and processing performance, the development of a new type of lightweight, fire-resistant, and tough engineering panel has become particularly urgent. This panel needs to meet multiple requirements, including lightweight, high toughness, and excellent fire resistance, to adapt to the diverse needs of modern architecture. Lightweight materials can reduce the overall weight of buildings and lessen structural load; high toughness ensures that the material is not easily broken during cutting and assembly; and excellent fire resistance is key to ensuring building safety. Summary of the Invention

[0005] To address the aforementioned problems, this invention provides a lightweight, fire-resistant, and tough board material that can be cut and spliced, along with its preparation method. This method uses high-temperature resistant fly ash and refractory fillers as binding materials, and polyurethane, epoxy resin, and organosilicon polymers as adhesives. Appropriate amounts of structural reinforcing materials, flame retardants, and toughening agents are added, and the proportions of each component are optimized to prepare a lightweight, fire-resistant, and tough multifunctional board material that can be cut and spliced. This material has significant market value and wide engineering applicability.

[0006] The present invention adopts the following technical solution:

[0007] A lightweight, fire-resistant, and resilient board that can be cut and spliced, wherein the lightweight, fire-resistant, and resilient board is composed of the following raw materials in parts by weight: 50-90 parts fly ash, 10-50 parts refractory filler, 5-20 parts organic adhesive, 2-15 parts reinforcing agent, 0.1-2 parts flame retardant, and 0.5-2 parts toughening agent.

[0008] Preferably, the organic adhesive is a mixture of epoxy resin, polyurethane and silicone resin; the weight ratio of the epoxy resin, polyurethane and silicone resin is 10:(0.5-2):(1-4).

[0009] Preferably, the reinforcing agent is a mixture of magnesium sulfate and chopped glass fibers; the weight ratio of magnesium sulfate to chopped glass fibers is 10:(1-5).

[0010] Preferably, the flame retardant is one of triethyl phosphate, tri(2-n-butoxyethyl) phosphate, and tricresyl phosphate.

[0011] Preferably, the fly ash has a particle size of 40 to 120 mesh.

[0012] Preferably, the refractory filler is one of vermiculite, diatomite, mullite, and refractory alumina; the vermiculite, diatomite, mullite, and refractory alumina are all ground to a particle size of 100-300 mesh.

[0013] Preferably, the toughening agent is one or more of nitrile rubber, polyethersulfone, and polysulfide rubber.

[0014] Preferably, the density of the cutable and splicable lightweight fire-resistant tough board is 1.2–1.9 g / cm³. 3 The calorific value of the cutable and splicable lightweight fireproof tough board is 1-3 MJ / kg.

[0015] A method for preparing a lightweight, fire-resistant, and flexible board that can be cut and spliced ​​specifically includes the following steps:

[0016] S1. Mix 50-90 parts by weight of fly ash and 5-20 parts by weight of organic adhesive, and stir evenly to prepare a primary slurry; the fly ash has a particle size of 40-120 mesh; the organic adhesive includes epoxy resin, polyurethane and silicone resin added in sequence; the weight ratio of epoxy resin, polyurethane and silicone resin is 10:(0.5-2):(1-4).

[0017] S2. Add 10-50 parts of refractory filler and 2-15 parts of reinforcing agent to the primary slurry in sequence, and stir evenly to prepare a secondary slurry; the refractory filler is one of vermiculite, diatomaceous earth, mullite, and refractory alumina with a mesh size of 100-300; the reinforcing agent includes magnesium sulfate and chopped glass fiber added in sequence; the weight ratio of magnesium sulfate to chopped glass fiber is 10:(1-5);

[0018] S3. Add 0.1 to 2 parts of flame retardant and 0.5 to 2 parts of toughening agent to the secondary slurry in sequence, and stir evenly to prepare a mature slurry; the flame retardant is one of triethyl phosphate, tris(2-n-butoxyethyl) phosphate, and tricresyl phosphate; the toughening agent is one or more of nitrile rubber, polyethersulfone, and polysulfide rubber.

[0019] S4. Inject the mature slurry into the mold, apply pressure and heat to form the mold;

[0020] S5. After demolding, the board is heated and aged to obtain a lightweight, fire-resistant, and tough board that can be cut and spliced.

[0021] Preferably, the hot pressing pressure for the pressing and heating molding in step S4 is 15-25 MPa, and the hot pressing temperature is 80-120°C; the aging temperature for the heating and aging in step S5 is 60-100°C, and the aging time is 12-24 h.

[0022] By adopting the above technical solution, the present invention has the following advantages compared with the prior art:

[0023] 1. This invention uses high-temperature resistant fly ash and refractory filler as binding materials, and polyurethane, epoxy resin and organosilicon polymers as adhesives. Appropriate amounts of structural reinforcing materials, flame retardants and toughening agents are added, and the proportions of each component are optimized to prepare a lightweight, fire-resistant, and tough multifunctional board that can be cut and spliced. It has great market value and wide engineering applicability.

[0024] 2. The lightweight, fire-resistant, and resilient board prepared by this invention can be cut and spliced ​​to produce different sizes and shapes according to user needs, and can be used in various spaces and scenarios. Furthermore, the addition of organic binders to the board effectively improves its toughness, making it less prone to breakage when spliced ​​after cutting, thus offering greater flexibility and fewer limitations. The fire-resistant board is made from high-temperature resistant fly ash and refractory fillers, with added flame retardants for better fire resistance, meeting the national standard A level. It is also lightweight, fireproof, waterproof, strong, cutable, resilient, insect and rodent resistant, corrosion resistant, aging resistant, and impact resistant, making it widely applicable in the construction and decoration fields. Attached Figure Description

[0025] Figure 1This is a flowchart illustrating the preparation process of the cutable and splicable lightweight fireproof and tough sheet material of the present invention.

[0026] Figure 2 This is a schematic diagram illustrating the cutting and splicing of the lightweight, fire-resistant, and tough sheet material that can be cut and spliced ​​according to the present invention. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0028] See Figures 1 to 2 .

[0029] Example 1

[0030] A method for preparing a lightweight, fire-resistant, and flexible board that can be cut and spliced ​​specifically includes the following steps:

[0031] S1. Mix 50 parts by weight of fly ash and 13 parts by weight of organic adhesive, and stir evenly to prepare a primary slurry; the particle size of the fly ash is 80-120 mesh; the organic adhesive includes epoxy resin, polyurethane and silicone resin added in sequence; the weight ratio of epoxy resin, polyurethane and silicone resin is 10:1:2.

[0032] S2. Add 25 parts of mullite and 9 parts of reinforcing agent to the primary slurry in sequence, and stir evenly to prepare the secondary slurry; the mullite has a particle size of 200-300 mesh; the reinforcing agent includes magnesium sulfate and chopped glass fiber added in sequence; the weight ratio of magnesium sulfate to chopped glass fiber is 6:3.

[0033] S3. Add 2 parts of flame retardant and 1 part of toughening agent to the secondary slurry in sequence, and stir evenly to prepare a mature slurry; the flame retardant is triethyl phosphate; the toughening agent is nitrile rubber;

[0034] S4. Inject the mature slurry into the mold and maintain it at a pressure of 20 MPa and a temperature of 100°C for 2 hours to form the mold.

[0035] S5. After demolding, the board is placed in a constant temperature drying oven and aged at 80℃ for 12 hours to obtain a lightweight, fire-resistant, and tough board that can be cut and spliced.

[0036] The obtained lightweight, fire-resistant, and tough boards that can be cut and spliced ​​were subjected to calorific value testing, and the fire resistance rating reached Class A.

[0037] Example 2

[0038] A method for preparing a lightweight, fire-resistant, and flexible board that can be cut and spliced ​​specifically includes the following steps:

[0039] S1. Mix 60 parts by weight of fly ash and 15 parts by weight of organic adhesive, and stir evenly to prepare a primary slurry; the particle size of the fly ash is 40-80 mesh; the organic adhesive includes epoxy resin, polyurethane and silicone resin added in sequence; the weight ratio of epoxy resin, polyurethane and silicone resin is 10:2:3.

[0040] S2. Add 15 parts of refractory alumina and 8 parts of reinforcing agent to the primary slurry in sequence, and stir evenly to prepare a secondary slurry; the particle size of the refractory alumina is 100-200 mesh; the reinforcing agent includes magnesium sulfate and chopped glass fiber added in sequence; the weight ratio of magnesium sulfate and chopped glass fiber is 7:1.

[0041] S3. Add 1.5 parts of flame retardant and 0.5 parts of toughening agent to the secondary slurry in sequence, and stir evenly to prepare a mature slurry; the flame retardant is tris(2-n-butyloxyethyl) phosphate; the toughening agent is polyethersulfone;

[0042] S4. Inject the mature slurry into the mold and maintain it at a pressure of 15 MPa and a temperature of 90°C for 1 hour to form the mold.

[0043] S5. After demolding, the board is placed in a constant temperature drying oven and aged at 60℃ for 24 hours to obtain a lightweight, fire-resistant, and tough board that can be cut and spliced.

[0044] The obtained lightweight, fire-resistant, and tough boards that can be cut and spliced ​​were subjected to calorific value testing, and the fire resistance rating reached Class A.

[0045] Example 3

[0046] A method for preparing a lightweight, fire-resistant, and flexible board that can be cut and spliced ​​specifically includes the following steps:

[0047] S1. Mix 80 parts by weight of fly ash and 9 parts by weight of organic adhesive, and stir evenly to prepare a primary slurry; the particle size of the fly ash is 60-100 mesh; the organic adhesive includes epoxy resin, polyurethane and silicone resin added in sequence; the weight ratio of epoxy resin, polyurethane and silicone resin is 10:1:1.

[0048] S2. Add 50 parts of vermiculite and 4 parts of reinforcing agent to the primary slurry in sequence, and stir evenly to prepare the secondary slurry; the vermiculite has a particle size of 100-300 mesh; the reinforcing agent includes magnesium sulfate and chopped glass fiber added in sequence; the weight ratio of magnesium sulfate to chopped glass fiber is 3:1.

[0049] S3. Add 0.5 parts of flame retardant and 0.5 parts of toughening agent to the secondary slurry in sequence, and stir evenly to prepare a mature slurry; the flame retardant is tricresyl phosphate; the toughening agent is polysulfide rubber;

[0050] S4. Inject the mature slurry into the mold and maintain it at a pressure of 25 MPa and a temperature of 80°C for 4 hours to form the mold.

[0051] S5. After demolding, the board is placed in a constant temperature drying oven and aged at 90℃ for 12 hours to obtain a lightweight, fire-resistant, and tough board that can be cut and spliced.

[0052] The obtained lightweight, fire-resistant, and tough boards that can be cut and spliced ​​were subjected to calorific value testing, and the fire resistance rating reached Class A.

[0053] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A lightweight, fire-resistant, and tough board that can be cut and spliced, characterized in that, The cutable and splicable lightweight fire-resistant tough board is composed of the following raw materials in parts by weight: 50-90 parts fly ash; Refractory filler 10-50 parts; 5-20 parts of organic adhesive; 2-15 parts of reinforcing agent; Flame retardant 0.1~2 parts; Toughening agent 0.5-2 parts; The organic adhesive is a mixture of epoxy resin, polyurethane and silicone resin; the weight ratio of epoxy resin, polyurethane and silicone resin is 10: (0.5~2):(1~4). The refractory filler is one of vermiculite, diatomite, mullite, and refractory alumina; the vermiculite, diatomite, mullite, and refractory alumina are all ground to a particle size of 100-300 mesh. The density of the cutable and splicable lightweight fire-resistant tough board is 1.2~1.9 g / cm³. 3 The calorific value of the cutable and splicable lightweight fireproof tough board is 1~3 MJ / kg.

2. The lightweight, fire-resistant, and tough board material that can be cut and spliced ​​as described in claim 1, characterized in that: The reinforcing agent is a mixture of magnesium sulfate and chopped glass fibers; the weight ratio of magnesium sulfate to chopped glass fibers is 10:(1~5).

3. The lightweight, fire-resistant, and tough board material that can be cut and spliced ​​as described in claim 1, characterized in that: The flame retardant is one of triethyl phosphate, tri(2-n-butoxyethyl) phosphate, and tricresyl phosphate.

4. The lightweight, fire-resistant, and tough board material that can be cut and spliced ​​as described in claim 1, characterized in that: The fly ash has a particle size of 40-120 mesh.

5. A lightweight, fire-resistant, and tough board material that can be cut and spliced ​​as described in claim 1, characterized in that: The toughening agent is one or more of nitrile rubber, polyethersulfone, and polysulfide rubber.

6. A method for preparing a cutable and splicable lightweight fire-resistant tough board as described in any one of claims 1-5, characterized in that, Specifically, the following steps are included: S1. Mix 50-90 parts by weight of fly ash and 5-20 parts by weight of organic adhesive, and stir evenly to prepare a primary slurry; the fly ash has a particle size of 40-120 mesh; the organic adhesive includes epoxy resin, polyurethane and silicone resin added in sequence; the weight ratio of epoxy resin, polyurethane and silicone resin is 10: (0.5-2): (1-4). S2. Add 10-50 parts of refractory filler and 2-15 parts of reinforcing agent to the primary slurry in sequence, and stir evenly to prepare a secondary slurry; the refractory filler is one of 100-300 mesh vermiculite, diatomaceous earth, mullite, and refractory alumina; the reinforcing agent includes magnesium sulfate and chopped glass fiber added in sequence; the weight ratio of magnesium sulfate to chopped glass fiber is 10:(1-5); S3. Add 0.1-2 parts of flame retardant and 0.5-2 parts of toughening agent to the secondary slurry in sequence, and stir evenly to prepare a mature slurry; the flame retardant is one of triethyl phosphate, tris(2-n-butoxyethyl) phosphate, and tricresyl phosphate; the toughening agent is one or more of nitrile rubber, polyethersulfone, and polysulfide rubber. S4. Inject the mature slurry into the mold, apply pressure and heat to form the mold; S5. After demolding, the board is heated and aged to obtain a lightweight, fire-resistant, and tough board that can be cut and spliced.

7. The method for preparing a cutable and splicable lightweight fire-resistant tough board as described in claim 6, characterized in that: The hot pressing pressure for the pressing and heating molding in step S4 is 15~25 MPa, and the hot pressing temperature is 80~120℃; the aging temperature for the heating and aging in step S5 is 60~100℃, and the aging time is 12~24h.

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