A paper-faced gypsum board

Abstract

The present application relates to the technical field of gypsum board, and specifically discloses a paper-faced gypsum board. A paper-faced gypsum board includes a board core and a facing paper bonded to both sides of the board core, wherein the board core includes the following raw materials in parts by weight: 60-100 parts of gypsum clinker; 20-30 parts of fly ash; 5-10 parts of glass fiber; 5-10 parts of silica aerogel particles; 1-5 parts of methyl silicone oil; 1-5 parts of starch; 0.2-3 parts of modified ammonium polyphosphate; 0.2-3 parts of foaming agent; 0.2-3 parts of water reducer; 0.2-3 parts of retarder; 30-50 parts of water; the modified ammonium polyphosphate is obtained by modifying ammonium polyphosphate by aluminum triisopropoxide. The paper-faced gypsum board of the present application effectively improves the flame retardant properties of the paper-faced gypsum board by adding modified ammonium polyphosphate without affecting the mechanical properties of the paper-faced gypsum board, thereby expanding the application scenarios of the paper-faced gypsum board.

Description

Technical Field

[0001] The present application relates to the technical field of gypsum boards, and more particularly, to a paper-faced gypsum board. Background Art

[0002] Gypsum board is a lightweight building sheet made primarily from natural gypsum and facing paper, mixed with appropriate amounts of fiber, starch, coagulant, foaming agent, and water. Due to its ease of processing, environmental friendliness, and space-saving properties, it is widely used in interior building materials and decorative finishes.

[0003] In related art, patent document CN112679178B discloses a paper-faced gypsum board comprising a core and a facing paper. The core is made from discarded ceramic mold gypsum, melamine resin, and ethylene glycol. The core may also include reinforcing fiber, polyvinyl alcohol emulsion, a water reducer, a foaming agent, Portland cement, a retarder, a coagulant, and starch. This paper-faced gypsum board utilizes these ingredients to compensate for the inherent shortcomings of discarded ceramic mold gypsum, ensuring that the gypsum board meets national standards while also effectively reusing discarded ceramic mold gypsum.

[0004] Since a certain amount of organic alcohol and resin material are added to the core of the above-mentioned gypsum board, the flame retardant performance of the above-mentioned gypsum board is poor, which limits its application in certain occasions with strict requirements on flame retardant performance. Summary of the Invention

[0005] In order to improve the flame retardant performance of gypsum board, the present application provides a gypsum board.

[0006] The present application provides a paper-faced gypsum board adopting the following technical solution:

[0007] A paper-faced gypsum board comprises a board core and facing papers bonded to both sides of the board core, wherein the board core comprises the following raw materials in parts by weight:

[0008] 60-100 parts of gypsum clinker;

[0009] 20-30 parts fly ash;

[0010] 5-10 parts of glass fiber;

[0011] 5-10 parts of silica aerogel particles;

[0012] 1-5 parts of methyl silicone oil;

[0013] 1-5 parts starch;

[0014] 0.2-3 parts of modified ammonium polyphosphate;

[0015] 0.2-3 parts of foaming agent;

[0016] 0.2-3 parts of water reducing agent;

[0017] Retarder 0.2-3 parts;

[0018] 30-50 parts water;

[0019] The modified ammonium polyphosphate is obtained by modifying ammonium polyphosphate with aluminum triisopropoxide.

[0020] By adopting the above technical solution, gypsum clinker is the main component of gypsum board, which provides the basic hardness and strength of gypsum board and ensures the load-bearing capacity and service life of gypsum board. Fly ash is an industrial waste. Its use as an additive here not only reduces production costs but also increases the density and durability of gypsum board. Glass fiber is used to enhance the tensile strength and toughness of gypsum board, and improves the crack resistance and impact resistance of gypsum board. Silica aerogel particles have excellent thermal insulation properties, which helps to improve the thermal insulation effect of gypsum board. Methyl silicone oil, as a lubricant, helps to improve the mixing uniformity and processing performance of raw materials, thereby improving production efficiency. Starch, as a binder, helps to bond between raw materials and improve the overall strength of gypsum board.

[0021] As a flame retardant, ammonium polyphosphate itself has good stability and has the advantages of low smoke and non-toxicity, but a large addition amount is required to meet the flame retardant requirements, thus significantly degrading the mechanical properties of the board core. In the present application scheme, ammonium polyphosphate is modified by aluminum triisopropylate. The resulting modified ammonium polyphosphate has high flame retardant properties and can meet the flame retardant requirements of gypsum board with a small addition amount without compromising the mechanical properties of the board core. Therefore, the modified ammonium polyphosphate can effectively improve the flame retardant properties of paper-faced gypsum board and expand the application scenarios of paper-faced gypsum board. By modifying ammonium polyphosphate with aluminum triisopropylate, during the combustion process, ammonium polyphosphate decomposes at high temperatures to produce phosphoric acid and ammonia. These decomposition products can absorb a large amount of heat and dilute the oxygen in the air, thereby reducing the combustion rate. In addition, the aluminum tri-secondary butoxide in the modified ammonium polyphosphate forms a dense aluminum oxide layer on the surface of the board core during combustion. This aluminum oxide layer has excellent thermal insulation properties and can effectively prevent heat from being transferred to the interior of the insulating layer, thereby slowing the heating rate of the material. The alumina layer also prevents or slows the diffusion of small molecular combustibles from the core, preventing the core material from coming into contact with oxygen in the air and potentially igniting. Furthermore, the alumina layer promotes the formation of a char layer, increasing its thickness and density, further enhancing the core's flame retardancy.

[0022] Optionally, the modified ammonium polyphosphate is prepared by the following method:

[0023] A. After mixing β-alanine, acetone, ammonium polyphosphate and deionized water, the pH value of the mixture was adjusted to 8 with aqueous ammonia to obtain a premixed solution;

[0024] B. Add emulsifier to the premixed solution, heat to 50°C, stir and react for 10-20 minutes, then add aluminum triisopropoxide, heat to 60°C, continue stirring for 2-4 hours, and then filter, wash and dry to obtain modified ammonium polyphosphate.

[0025] By employing this technical solution, β-alanine facilitates the uniform dispersion of acetone and ammonium polyphosphate in deionized water. Acetone, as an auxiliary raw material, enhances the compatibility of the modified ammonium polyphosphate with the board core raw materials. The emulsifier disperses raw materials such as ammonium polyphosphate and aluminum triisopropoxide into fine particles, improving their uniformity within the raw materials. The stirring reaction conditions control the particle size and morphology of the modified ammonium polyphosphate, thereby enhancing its flame retardant effect within the board core.

[0026] Optionally, in step A, the mass ratio of β-alanine, acetone, ammonium polyphosphate and deionized water is (0.5-1):2:1:5.

[0027] By adopting this technical solution and precisely controlling the mass ratio of each raw material, sufficient contact and reaction of the reaction materials can be ensured, avoiding problems such as raw material waste and incomplete reaction. This helps to improve the yield and quality stability of the modified ammonium polyphosphate. The optimized mass ratio further enhances the dispersibility and compatibility of the modified ammonium polyphosphate in gypsum board, which helps to enhance its flame retardant effect in gypsum board and improve the overall flame retardant performance of the gypsum board.

[0028] Optionally, the emulsifier in step B is sodium stearate, and the amount of the emulsifier added is 3%-5% of the mass of the ammonium polyphosphate.

[0029] By adopting the above technical solution, sodium stearate, as an emulsifier, has excellent dispersing and stabilizing effects. It can disperse raw materials such as ammonium polyphosphate and aluminum triisopropoxide into fine particles, improving their dispersion uniformity in the reaction system. This helps ensure sufficient contact and reaction of the reaction raw materials, improving the yield and quality stability of the modified ammonium polyphosphate. By controlling the addition amount of the emulsifier, the particle size and morphology of the modified ammonium polyphosphate can be further optimized. The appropriate amount of emulsifier can ensure uniform dispersion of the raw materials in the reaction system, avoiding agglomeration and precipitation. This helps improve the dispersibility and compatibility of the modified ammonium polyphosphate in gypsum board, further enhancing its flame retardant effect in gypsum board.

[0030] Optionally, the amount of aluminum triisopropoxide added in step B is 6%-10% of the mass of ammonium polyphosphate.

[0031] By adopting the above technical scheme, first, by controlling the addition range of aluminum triisopropylate, it is possible to ensure that it fully reacts with raw materials such as ammonium polyphosphate to generate a modified ammonium polyphosphate with efficient flame retardancy. An appropriate amount of aluminum triisopropylate can significantly improve the flame retardancy of modified ammonium polyphosphate, so that it can meet the flame retardancy requirements of gypsum board under a smaller addition amount. Secondly, the above-mentioned aluminum triisopropylate addition range helps to reduce production costs and improve production efficiency. By reducing unnecessary waste of raw materials and reaction time, production costs can be significantly reduced and economic benefits can be improved. Simultaneously, the preparation process after optimization also helps to improve the productive rate and quality stability of modified ammonium polyphosphate.

[0032] Optionally, the foaming agent is any one of sodium lauryl sulfate, sodium bicarbonate and azodicarbonamide, or a combination of several of them.

[0033] Optionally, the raw materials of the board core further include 10-20 parts of pearlite soil.

[0034] By adopting the above-mentioned technical solution, the addition of perlite soil can also improve the strength and durability of gypsum board. Perlite soil has high strength and hardness, which can enhance the overall strength and durability of gypsum board, making it more suitable for various harsh environments and heavy loads. In addition, when perlite is heated to high temperatures, it expands and becomes a lightweight porous material. This expansion process can increase its volume by up to 20 times, forming a low-density material with excellent thermal insulation properties, further enhancing the flame retardancy of gypsum board.

[0035] Optionally, the silica aerogel particles have a particle size of 5-50 nm.

[0036] In summary, this application has the following beneficial effects:

[0037] 1. The gypsum board of the present application adds modified ammonium polyphosphate as a flame retardant in the board core, and the ammonium polyphosphate is modified by aluminum triisopropylate, which significantly improves the flame retardant properties of the gypsum board. Modified ammonium polyphosphate can generate phosphoric acid and ammonia during the combustion process, absorb a large amount of heat and dilute the oxygen in the air, thereby reducing the combustion rate. At the same time, the aluminum tri-secondary butoxide formed during the modification process will form a dense aluminum oxide layer on the surface of the board core when burning. This aluminum oxide layer has excellent thermal insulation properties, can effectively prevent heat from being transferred to the inside of the board core, slow down the heating rate of the material, and prevent or delay the diffusion of small molecular combustibles from the inside of the board core to the outside, avoiding the board core material from contacting with oxygen in the air and burning. In addition, the aluminum oxide layer can also promote the formation of a carbon layer, increase the thickness and density of the carbon layer, further improving the flame retardant properties of the gypsum board, so that it can be widely used in construction and decoration fields with high requirements for flame retardant properties.

[0038] 2. The method for preparing modified ammonium polyphosphate provided in the present application ensures the efficient preparation of modified ammonium polyphosphate by accurately controlling the mass ratio of the reaction raw materials, the type and addition amount of the emulsifier, and the addition amount of aluminum triisopropylate. This preparation method not only improves the yield and quality stability of modified ammonium polyphosphate, but also optimizes its dispersibility and compatibility in gypsum board. Since the dispersion of modified ammonium polyphosphate in gypsum board is more uniform, its flame retardant effect is significantly enhanced, so that gypsum board can meet the flame retardant requirements at a smaller addition amount without causing losses to the mechanical properties of the board core. The adoption of this preparation method not only improves the flame retardant properties of gypsum board, but also reduces production costs, improves production efficiency, and provides strong support for the promotion and application of gypsum board.

[0039] 3. By adding a variety of functional raw materials, such as silica aerogel particles and perlite, to the raw materials of the gypsum board of this application, the comprehensive performance of the gypsum board is further improved. Silica aerogel particles have excellent thermal insulation properties, which help to improve the thermal insulation effect of the gypsum board, making it more suitable for buildings and decoration occasions that require thermal insulation. The addition of perlite improves the strength and durability of the gypsum board, making it more suitable for various harsh environments and heavy-load occasions, and perlite further enhances the flame retardant properties of the gypsum board. The addition of these functional raw materials not only enriches the application scenarios of the gypsum board, but also improves its market competitiveness. DETAILED DESCRIPTION

[0040] The present application is further described in detail below with reference to the embodiments.

[0041] Unless otherwise specified, all raw materials used in the preparations, examples, and comparative examples of this application were commercially available. Glass fiber was purchased from Hangzhou Gaoke Composite Materials Co., Ltd.; silica aerogel particles, type KN-6883, were purchased from Langfang Kenuo Building Materials Co., Ltd.; and water reducers and retarders were purchased from Guangdong Hong'an Building Materials Co., Ltd.

[0042] Preparation example of modified ammonium polyphosphate

[0043] Preparation Example 1

[0044] Modified ammonium polyphosphate is prepared by the following method:

[0045] A. Mix 0.5 kg of β-alanine, 2 kg of acetone, 1 kg of ammonium polyphosphate, and 5 kg of deionized water, and adjust the pH of the mixture to 8 with aqueous ammonia to obtain a premixed solution;

[0046] B. Add 0.03 kg of sodium stearate to the premixed solution, heat it to 50 ° C, stir and react for 10 minutes, then add 0.06 kg of aluminum triisopropoxide, heat it to 60 ° C, continue stirring for 2 hours, and then filter, wash and dry to obtain modified ammonium polyphosphate.

[0047] Preparation Example 2

[0048] Modified ammonium polyphosphate is prepared by the following method:

[0049] A. Mix 0.7 kg of β-alanine, 2 kg of acetone, 1 kg of ammonium polyphosphate, and 5 kg of deionized water, and adjust the pH of the mixture to 8 with aqueous ammonia to obtain a premixed solution;

[0050] B. Add 0.04 kg of sodium stearate to the premixed solution, heat it to 50 ° C, stir and react for 15 minutes, then add 0.08 kg of aluminum triisopropoxide, heat it to 60 ° C, continue stirring for 3 hours, and then filter, wash and dry to obtain modified ammonium polyphosphate.

[0051] Preparation Example 3

[0052] Modified ammonium polyphosphate is prepared by the following method:

[0053] A. Mix 1.0 kg of β-alanine, 2 kg of acetone, 1 kg of ammonium polyphosphate, and 5 kg of deionized water, and adjust the pH of the mixture to 8 with aqueous ammonia to obtain a premixed solution;

[0054] B. Add 0.05 kg of sodium stearate to the premixed solution, heat it to 50°C, stir and react for 20 minutes, then add 0.1 kg of aluminum triisopropoxide, heat it to 60°C, continue stirring for 4 hours, and then filter, wash and dry to obtain modified ammonium polyphosphate.

[0055] Preparation Example 4

[0056] The modified ammonium polyphosphate is different from that of Preparation Example 3 in that an equal amount of methylcyclosiloxane is used in step B instead of aluminum triisopropoxide.

[0057] Preparation Example 5

[0058] The modified ammonium polyphosphate is different from that of Preparation Example 3 in that an equal amount of sodium tartrate is used in place of β-alanine in step A.

[0059] Example

[0060] Example 1

[0061] A paper-faced gypsum board comprises a board core and facing paper bonded to both sides of the board core, wherein the facing paper is made of wood pulp paper. The raw material components and proportions of the board core are shown in Table 1. The modified ammonium polyphosphate is the modified ammonium polyphosphate prepared in Preparation Example 1, and the foaming agent is sodium lauryl sulfate.

[0062] The paper-faced gypsum board is prepared by the following method:

[0063] S1. Gypsum clinker, fly ash, glass fiber, silica aerogel particles, methyl silicone oil, starch, modified ammonium polyphosphate, foaming agent, water reducer, retarder and water are mixed and put into a stirring device and stirred at a speed of 30 r / min for 5 minutes to form a uniform slurry;

[0064] S2. Pour the slurry into the mold, distribute the slurry evenly by vibration or scraper, and remove bubbles, and wait for the slurry to solidify and form the board core;

[0065] S3. Attach the facing paper to both sides of the board core with a phenolic resin adhesive, and perform hot pressing at a temperature of 45°C to tightly bond the facing paper to the board core. Cut and trim the bonded paper-faced gypsum board.

[0066] Example 2

[0067] A paper-faced gypsum board comprises a board core and facing paper bonded to both sides of the board core, wherein the facing paper is made of wood pulp paper. The raw material components and proportions of the board core are shown in Table 1. The modified ammonium polyphosphate is the modified ammonium polyphosphate prepared in Preparation Example 2, and the foaming agent is sodium bicarbonate.

[0068] The paper-faced gypsum board is prepared by the following method:

[0069] S1. Gypsum clinker, fly ash, glass fiber, silica aerogel particles, methyl silicone oil, starch, modified ammonium polyphosphate, foaming agent, water reducer, retarder and water are mixed and put into a stirring device and stirred at a speed of 40 r / min for 7 minutes to form a uniform slurry;

[0070] S2. Pour the slurry into the mold, distribute the slurry evenly by vibration or scraper, and remove bubbles, and wait for the slurry to solidify and form the board core;

[0071] S3. Attach the facing paper to both sides of the board core with a phenolic resin adhesive, and perform hot pressing at a temperature of 40°C to tightly bond the facing paper to the board core. Cut and trim the bonded paper-faced gypsum board.

[0072] Example 3

[0073] A paper-faced gypsum board comprises a board core and facing paper bonded to both sides of the board core, wherein the facing paper is made of wood pulp paper. The raw material components and proportions of the board core are shown in Table 1. The modified ammonium polyphosphate prepared in Preparation Example 3 is used as the modified ammonium polyphosphate, and the foaming agent is azodicarbonamide.

[0074] The paper-faced gypsum board is prepared by the following method:

[0075] S1. Gypsum clinker, fly ash, glass fiber, silica aerogel particles, methyl silicone oil, starch, modified ammonium polyphosphate, foaming agent, water reducer, retarder and water are mixed and put into a stirring device and stirred at a speed of 40 r / min for 7 minutes to form a uniform slurry;

[0076] S2. Pour the slurry into the mold, distribute the slurry evenly by vibration or scraper, and remove bubbles, and wait for the slurry to solidify and form the board core;

[0077] S3. Attach the facing paper to both sides of the board core with a phenolic resin adhesive, and perform hot pressing at a temperature of 40°C to tightly bond the facing paper to the board core. Cut and trim the bonded paper-faced gypsum board.

[0078] Table 1 Raw material components and dosage of the core plate in Examples 1-3 (kg)

[0079]

[0080] Example 4

[0081] A gypsum board is different from Example 3 in that the core material of the board in this example further includes 10 kg of perlite soil, and the perlite soil is added in step S1 during the preparation of the gypsum board.

[0082] Example 5

[0083] A gypsum board is different from Example 3 in that the core material of the board in this example further includes 15 kg of perlite soil, and the perlite soil is added in step S1 during the preparation of the gypsum board.

[0084] Example 6

[0085] A gypsum board is different from Example 3 in that the core material of the board in this example further includes 20 kg of perlite soil, and the perlite soil is added in step S1 during the preparation of the gypsum board.

[0086] Comparative Example

[0087] Comparative Example 1

[0088] The paper-faced gypsum board was prepared according to the method specified in Example 1 of the patent document with publication number CN112679178B and titled “A Paper-faced Gypsum Board”.

[0089] Comparative Example 2

[0090] A paper-faced gypsum board, which differs from Example 3 in that the modified ammonium polyphosphate is the modified ammonium polyphosphate prepared in Preparation Example 4.

[0091] Comparative Example 3

[0092] A paper-faced gypsum board, which differs from Example 3 in that the modified ammonium polyphosphate is the modified ammonium polyphosphate prepared in Preparation Example 5.

[0093] Comparative Example 4

[0094] A paper-faced gypsum board, which differs from Example 3 in that unmodified ammonium polyphosphate is used instead of modified ammonium polyphosphate.

[0095] Performance testing

[0096] The performance tests were conducted on the 15 mm thick gypsum boards prepared in Examples 1-6 and Comparative Examples 1-4. The results are shown in Table 2.

[0097] Table 2 Test results of gypsum boards in Examples 1-6 and Comparative Examples 1-4

[0098]

[0099] Combining Examples 1-3 and Comparative Example 1, it can be seen that the fire stability of the gypsum boards prepared in the examples of the present application is maintained at more than 230 minutes, while the fire stability of the gypsum boards in Comparative Example 1 is only 32 minutes, indicating that the gypsum boards in the examples of the present application have better flame retardant properties, and the enhanced flame retardant properties will not affect the mechanical properties of the gypsum boards.

[0100] Comparing Examples 4-6 with Example 3 reveals that Examples 4-6 incorporate varying amounts of perlite into the core material. As the amount of perlite added increases, the fire stability of the gypsum board increases, from 262 minutes to 268 minutes. This demonstrates that the addition of perlite further enhances the flame retardancy of the gypsum board. Furthermore, mechanical properties such as breaking load, shear force, and impact toughness also improve, demonstrating that the addition of perlite significantly improves the overall strength and durability of the gypsum board.

[0101] Comparative Examples 2 and 3 used the modified ammonium polyphosphate prepared in Preparation Examples 4 and 5, respectively. This resulted in relatively low fire stability of the gypsum board. Specifically, the fire stability of Comparative Example 2 was 165 minutes, while that of Comparative Example 3 was 196 minutes. This demonstrates that the preparation method of the modified ammonium polyphosphate and the selection of raw materials have a significant impact on the flame retardancy of the gypsum board.

[0102] Finally, Comparative Example 4 used unmodified ammonium polyphosphate instead of modified ammonium polyphosphate. Its fire stability was only 95 minutes, far lower than the fire stability of the gypsum boards in Examples 1-3. This further demonstrates the effectiveness of modified ammonium polyphosphate in improving the flame retardancy of paper-faced gypsum board.

[0103] This specific embodiment is merely an explanation of the present application and is not a limitation of the present application. After reading this specification, those skilled in the art may make non-creative modifications to the present embodiment as needed, but as long as they are within the scope of the claims of the present application, they are protected by the patent law.

Claims

1. A paper-faced gypsum board comprising a board core and facing papers bonded to both sides of the board core, characterized in that: The core comprises the following raw materials in parts by weight: 60-100 parts of gypsum clinker; 20-30 parts fly ash; Glass fiber 5-10 parts; 5-10 parts of silica aerogel particles; 1-5 parts of methyl silicone oil; 1-5 parts starch; 0.2-3 parts of modified ammonium polyphosphate; 0.2-3 parts of foaming agent; 0.2-3 parts of water reducing agent; Retarder 0.2-3 parts; 30-50 parts water; The modified ammonium polyphosphate is prepared by the following method: A. After mixing β-alanine, acetone, ammonium polyphosphate and deionized water, the pH value of the mixture was adjusted to 8 with aqueous ammonia to obtain a premixed solution; B. Add an emulsifier to the premixed solution, heat it, stir it to react, then add aluminum triisopropoxide, continue heating it, continue stirring it, then filter it, wash it, and dry it to obtain modified ammonium polyphosphate.

2. The gypsum board according to claim 1, characterized in that: In step B, the temperature is raised to 50° C.; the stirring reaction time is 10-20 min; the temperature is further raised to 60° C.; and the stirring reaction time is 2-4 h.

3. The gypsum board according to claim 1, characterized in that: In step A, the mass ratio of β-alanine, acetone, ammonium polyphosphate and deionized water is (0.5-1):2:1:

5.

4. The gypsum board according to claim 1, characterized in that: In step B, the emulsifier is sodium stearate, and the amount of the emulsifier added is 3%-5% of the mass of the ammonium polyphosphate.

5. The gypsum board according to claim 1, characterized in that: In step B, the amount of aluminum triisopropoxide added is 6%-10% of the mass of ammonium polyphosphate.

6. The gypsum board according to claim 1, characterized in that: The foaming agent is any one of sodium lauryl sulfate, sodium bicarbonate and azodicarbonamide or a combination of several of them.

7. The gypsum board according to claim 1, characterized in that: The raw materials of the board core also include 10-20 parts of pearlite soil.

8. The gypsum board according to claim 1, characterized in that: The particle size of the silica aerogel particles is 5-50 nm.

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