Fiber reinforced gypsum board and preparation method thereof

Abstract

The invention discloses a fiber reinforced gypsum board and a preparation method, and relates to the technical field of gypsum boards. The invention relates to a fiber reinforced gypsum board, which comprises the following components by weight: 58-68 parts of gypsum; 8 to 12 parts of composite fiber; 4 to 8 parts of attapulgite; 3-5 parts of silica sol; 0.2 to 0.5 part of a foaming agent; 0.12 to 0.18 part of a retarder; 1.8 to 2.5 parts of a flame retardant; 15 to 18 parts of water; in the composite fiber, the basalt fiber accounts for 50-70 wt%, and the regenerated cellulose fiber accounts for 30-50 wt%. The long basalt fiber is added to provide macroscopic breaking strength, and the short regenerated cellulose fiber provides microcracks and provides microscopic breaking strength; therefore, the gypsum board with high breaking strength is prepared; by adding the attapulgite, a part of the regenerated cellulose fiber extends into a long and narrow channel in the attapulgite, and a part of the regenerated cellulose fiber is exposed to be combined with other raw materials in the gypsum board, so that the strength of the gypsum board is enhanced, the damp deformation rate of the gypsum board is reduced, and the thermal insulation performance of the gypsum board is improved.

Description

Technical Field

[0001] This application relates to the technical field of gypsum boards, and particularly to a fiber-reinforced gypsum board and a preparation method thereof. Background Art

[0002] As a common building material, gypsum boards are widely used in building walls, ceilings and other structures due to their light weight, fire resistance, sound insulation and other characteristics. Traditional gypsum boards mainly consist of a gypsum core and a paper or fiber surface layer. Although they have certain strength and construction convenience, there are still deficiencies in some application scenarios.

[0003] Insufficient strength of traditional gypsum boards: The flexural strength of traditional gypsum boards is relatively low, and they are prone to deformation and damage especially in humid environments; they are easily damaged during construction, increasing the construction difficulty and cost.

[0004] To overcome the above problems, various improvement schemes have been proposed in the prior art, such as: adding fiber materials; using a waterproof coating or moisture-proof treatment on the surface; compounding gypsum boards with other materials (such as cement boards, metal boards) to enhance the overall performance, etc.

[0005] Although the prior art has improved the performance of gypsum boards to a certain extent, there are still problems such as uneven fiber dispersion, affecting the reinforcement effect; the high cost of high-performance fiber materials, restricting their wide application; and complex processes. Summary of the Invention

[0006] In order to solve at least one of the above technical problems and develop a gypsum board with low cost, high strength and good moisture resistance, this application provides a fiber-reinforced gypsum board and a preparation method thereof.

[0007] On the one hand, a fiber-reinforced gypsum board provided by this application includes the following components in parts by weight:

[0008] Gypsum: 58 - 68 parts;

[0009] Composite fiber: 8 - 12 parts;

[0010] Attapulgite: 4 - 8 parts;

[0011] Silica sol: 3 - 5 parts;

[0012] Foaming agent: 0.2 - 0.5 part;

[0013] Retarder: 0.12 - 0.18 part;

[0014] Flame retardant: 1.8 - 2.5 parts;

[0015] Water: 15 - 18 parts;

[0016] In the composite fiber, the basalt fiber accounts for 50-70 wt%, and the regenerated cellulose fiber accounts for 30-50 wt%.

[0017] Optionally, the weight ratio of the composite fiber to the attapulgite is 1.6-2.2:1.

[0018] Optionally, in the composite fiber, the basalt fiber accounts for 65 wt%, and the regenerated cellulose fiber accounts for 35 wt%.

[0019] Optionally, the particle size of the attapulgite is 2-200 μm.

[0020] Optionally, the particle size of the silica sol is 20-50 nm.

[0021] Optionally, the foaming agent uses a protein-based foaming agent;

[0022] And / or, the retarder uses trisodium citrate;

[0023] And / or, the flame retardant uses a zinc borate + magnesium hydroxide composite system flame retardant.

[0024] In the second aspect, the present application provides a preparation method of the above gypsum board, including the following steps:

[0025] S1. Fiber pretreatment

[0026] For basalt fiber: surface treatment is carried out with a silane coupling agent and an ethanol solution;

[0027] For regenerated cellulose fiber: surface treatment is carried out with a 2% NaOH solution;

[0028] S2. Slurry preparation

[0029] 2.1. Dry mixing stage: Gypsum, flame retardant and attapulgite are stirred and mixed;

[0030] 2.2. Wet mixing stage: The retarder and water are added, and the foaming agent is injected synchronously;

[0031] 2.3. Fiber incorporation: The basalt fiber and regenerated cellulose fiber treated in S1 and silica sol are added in sequence

[0032] S3. Casting and molding

[0033] Vacuum vibration molding is adopted, and the initial setting time is 12-15 min;

[0034] S4. Gradient drying

[0035] Curing treatment is carried out, and then drying treatment is carried out;

[0036] S5. Post-treatment

[0037] The roller press applies pressure for surface densification.

[0038] Optionally, in the step S2, the stirring speed is 1200 rpm and the stirring time is 3 min.

[0039] Optionally, in the step S4, the curing treatment is: curing at 40°C / RH70% for 2 h;

[0040] And / or, the drying treatment is: hot air circulation drying at 60°C.

[0041] Optionally, in the step S5, the pressure applied by the roller press is 0.5 MPa.

[0042] In summary, the present invention includes at least one of the following beneficial technical effects:

[0043] 1. By adding longer basalt fibers to provide macroscopic flexural strength and shorter regenerated cellulose fibers to provide microcracks, microscopic flexural strength is provided; thus, a gypsum board with high flexural strength is prepared.

[0044] 2. By adding attapulgite clay and compounding it with regenerated cellulose fibers, part of the regenerated cellulose fibers extend into the narrow channels inside the attapulgite clay, and part are exposed to combine with other raw materials in the gypsum board, further strengthening the strength of the gypsum board. After adsorbing a small amount of water, water molecules fill the channels, causing one end of the regenerated cellulose fibers to be pressed tightly in the channels, reducing the moisture-induced deformation rate of the gypsum board.

[0045] 3. By adding attapulgite clay and utilizing the porous channels inside the attapulgite clay, the heat insulation performance can be effectively improved, enhancing the heat preservation performance of the gypsum board. Detailed Embodiments

[0046] The following further elaborates on the present application with reference to embodiments.

[0047] In the following embodiments of the present application, unless otherwise specified, the main components involved are all purchased from commercially available products.

[0048] Gypsum: High-strength α-hemihydrate desulfurized gypsum with a purity of ≥92%.

[0049] Foaming agent: Exemplarily, a protein-based foaming agent is used, purchased from Yantai Chilong Building Energy Conservation Technology Co., Ltd.

[0050] Flame retardant: Exemplarily, a composite flame retardant system of zinc borate + magnesium hydroxide is used; purchased from Yantai Aiful Fire Retardant Technology Co., Ltd.

[0051] Basalt fibers: 6 mm grade; Exemplarily, surface treatment is carried out using a silane coupling agent and an ethanol solution.

[0052] Regenerated cellulose fiber: at the 20-μm level; exemplary surface treatment is carried out with a 2% NaOH solution. Specific embodiments

[0054] Example 1

[0055] This example is used to prepare a fiber-reinforced gypsum board, as follows.

[0056] Mix 5.8 kg of gypsum, 0.2 kg of flame retardant, and 0.4 kg of attapulgite with stirring at 1200 rpm for 3 min; add 15 g of retarder and 1.55 kg of water, and simultaneously inject 30 g of foaming agent; add 1.2 kg of composite fiber (where basalt fiber accounts for 65 wt% and regenerated cellulose fiber accounts for 35 wt%), 0.3 kg of silica sol; use vacuum vibration molding (vacuum degree -0.08 MPa, vibration frequency 50 Hz), initial setting time is 15 min; cure at 40°C / RH70% for 2 h; dry with hot air circulation at 60°C; apply a pressure of 0.5 MPa with a roller press for surface densification. A fiber-reinforced gypsum board is prepared.

[0057] Example 2

[0058] This example is used to prepare a fiber-reinforced gypsum board, as follows.

[0059] Mix 6.0 kg of gypsum, 0.2 kg of flame retardant, and 0.5 kg of attapulgite with stirring at 1200 rpm for 3 min; add 15 g of retarder and 1.55 kg of water, and simultaneously inject 30 g of foaming agent; add 1.1 kg of composite fiber (where basalt fiber accounts for 65 wt% and regenerated cellulose fiber accounts for 35 wt%), 0.3 kg of silica sol; use vacuum vibration molding (vacuum degree -0.08 MPa, vibration frequency 50 Hz), initial setting time is 15 min; cure at 40°C / RH70% for 2 h; dry with hot air circulation at 60°C; apply a pressure of 0.5 MPa with a roller press for surface densification. A fiber-reinforced gypsum board is prepared.

[0060] Example 3

[0061] This example is used to prepare a fiber-reinforced gypsum board, as follows.

[0062] Mix 6.2 kg of gypsum, 0.2 kg of flame retardant, and 0.6 kg of attapulgite clay at 1200 rpm for 3 min; add 15 g of retarder and 1.55 kg of water, and simultaneously inject 30 g of foaming agent; add 1.0 kg of composite fiber (where basalt fiber accounts for 65 wt%, and regenerated cellulose fiber accounts for 35 wt%), 0.3 kg of silica sol; use vacuum vibration molding (vacuum degree -0.08 MPa, vibration frequency 50 Hz), the initial setting time is 15 min; cure at 40°C / RH70% for 2 h; dry with hot air circulation at 60°C; apply a pressure of 0.5 MPa with a roller press for surface densification. A fiber-reinforced gypsum board is prepared.

[0063] Example 4

[0064] This example is used to prepare a fiber-reinforced gypsum board, which is as follows.

[0065] Mix 6.5 kg of gypsum, 0.2 kg of flame retardant, and 0.7 kg of attapulgite clay at 1200 rpm for 3 min; add 15 g of retarder and 1.55 kg of water, and simultaneously inject 30 g of foaming agent; add 0.9 kg of composite fiber (where basalt fiber accounts for 65 wt%, and regenerated cellulose fiber accounts for 35 wt%), 0.3 kg of silica sol; use vacuum vibration molding (vacuum degree -0.08 MPa, vibration frequency 50 Hz), the initial setting time is 15 min; cure at 40°C / RH70% for 2 h; dry with hot air circulation at 60°C; apply a pressure of 0.5 MPa with a roller press for surface densification. A fiber-reinforced gypsum board is prepared.

[0066] Example 5

[0067] This example is used to prepare a fiber-reinforced gypsum board, which is as follows.

[0068] Mix 6.8 kg of gypsum, 0.2 kg of flame retardant, and 0.8 kg of attapulgite clay at 1200 rpm for 3 min; add 15 g of retarder and 1.55 kg of water, and simultaneously inject 30 g of foaming agent; add 0.8 kg of composite fiber (where basalt fiber accounts for 65 wt%, and regenerated cellulose fiber accounts for 35 wt%), 0.3 kg of silica sol; use vacuum vibration molding (vacuum degree -0.08 MPa, vibration frequency 50 Hz), the initial setting time is 15 min; cure at 40°C / RH70% for 2 h; dry with hot air circulation at 60°C; apply a pressure of 0.5 MPa with a roller press for surface densification. A fiber-reinforced gypsum board is prepared.

[0069] Perform performance tests on the gypsum boards prepared in the above Examples 1 to 5, and the results are shown in Table 1 (where the weight ratio is the weight ratio of the composite fiber to the attapulgite clay).

[0070] Table 1

[0071]

[0072] From Examples 1 to 5 and Table 1, it can be seen that the gypsum board prepared in this application has high flexural strength, low moisture absorption deformation rate, low thermal conductivity, high fire resistance limit, and excellent comprehensive performance. And from the parameters in Table 1, it can be seen that the comprehensive performance of Example 2 and Example 3 is more excellent than that of other examples. Therefore, the inventor made the following Examples 6 to 13 for further analysis, which are as follows.

[0073] Examples 6 to 9 are based on Example 2, and only the addition amount of attapulgite is changed, which is as follows.

[0074] Example 6

[0075] This example is used to prepare a fiber-reinforced gypsum board, which is as follows.

[0076] Mix 6.0 kg of gypsum, 0.2 kg of flame retardant and 0.4 kg of attapulgite at 1200 rpm for 3 min; add 15 g of retarder and 1.55 kg of water, and simultaneously inject 30 g of foaming agent; add 1.1 kg of composite fiber (where basalt fiber accounts for 65 wt%, and regenerated cellulose fiber accounts for 35 wt%), 0.3 kg of silica sol; use vacuum vibration molding (vacuum degree -0.08 MPa, vibration frequency 50 Hz), the initial setting time is 15 min; cure at 40°C / RH70% for 2 h; dry with 60°C hot air circulation; apply a pressure of 0.5 MPa with a roller press for surface densification. A fiber-reinforced gypsum board is prepared.

[0077] Example 7

[0078] This example is used to prepare a fiber-reinforced gypsum board, which is as follows.

[0079] Mix 6.0 kg of gypsum, 0.2 kg of flame retardant and 0.6 kg of attapulgite at 1200 rpm for 3 min; add 15 g of retarder and 1.55 kg of water, and simultaneously inject 30 g of foaming agent; add 1.1 kg of composite fiber (where basalt fiber accounts for 65 wt%, and regenerated cellulose fiber accounts for 35 wt%), 0.3 kg of silica sol; use vacuum vibration molding (vacuum degree -0.08 MPa, vibration frequency 50 Hz), the initial setting time is 15 min; cure at 40°C / RH70% for 2 h; dry with 60°C hot air circulation; apply a pressure of 0.5 MPa with a roller press for surface densification. A fiber-reinforced gypsum board is prepared.

[0080] Example 8

[0081] This example is used to prepare a fiber-reinforced gypsum board, which is as follows.

[0082] Mix 6.0 kg of gypsum, 0.2 kg of flame retardant, and 0.7 kg of attapulgite at 1200 rpm for 3 min; add 15 g of retarder and 1.55 kg of water, and simultaneously inject 30 g of foaming agent; add 1.1 kg of composite fiber (where basalt fiber accounts for 65 wt%, and regenerated cellulose fiber accounts for 35 wt%), 0.3 kg of silica sol; use vacuum vibration molding (vacuum degree -0.08 MPa, vibration frequency 50 Hz), the initial setting time is 15 min; cure at 40°C / RH70% for 2 h; dry with hot air circulation at 60°C; apply a pressure of 0.5 MPa with a roller press for surface densification. A fiber-reinforced gypsum board is prepared.

[0083] Example 9

[0084] This example is used to prepare a fiber-reinforced gypsum board, which is as follows.

[0085] Mix 6.0 kg of gypsum, 0.2 kg of flame retardant, and 0.8 kg of attapulgite at 1200 rpm for 3 min; add 15 g of retarder and 1.55 kg of water, and simultaneously inject 30 g of foaming agent; add 1.1 kg of composite fiber (where basalt fiber accounts for 65 wt%, and regenerated cellulose fiber accounts for 35 wt%), 0.3 kg of silica sol; use vacuum vibration molding (vacuum degree -0.08 MPa, vibration frequency 50 Hz), the initial setting time is 15 min; cure at 40°C / RH70% for 2 h; dry with hot air circulation at 60°C; apply a pressure of 0.5 MPa with a roller press for surface densification. A fiber-reinforced gypsum board is prepared.

[0086] Perform performance tests on the gypsum boards prepared in Examples 6 - 9 above, and the results are shown in Table 2 (where the weight ratio is the weight ratio of composite fiber to attapulgite).

[0087] Table 2

[0088]

[0089]

[0090] In Examples 10 - 13, based on Example 3, only the addition amount of attapulgite is changed, which is as follows.

[0091] Example 10

[0092] This example is used to prepare a fiber-reinforced gypsum board, which is as follows.

[0093] Mix 6.2 kg of gypsum, 0.2 kg of flame retardant, and 0.4 kg of attapulgite clay at 1200 rpm for 3 min; add 15 g of retarder and 1.55 kg of water, and simultaneously inject 30 g of foaming agent; add 1.0 kg of composite fiber (where basalt fiber accounts for 65 wt%, and regenerated cellulose fiber accounts for 35 wt%), 0.3 kg of silica sol; use vacuum vibration molding (vacuum degree -0.08 MPa, vibration frequency 50 Hz), the initial setting time is 15 min; cure at 40°C / RH70% for 2 h; dry with hot air circulation at 60°C; apply a pressure of 0.5 MPa with a roller press for surface densification. A fiber-reinforced gypsum board is prepared.

[0094] Example 11

[0095] This example is used to prepare a fiber-reinforced gypsum board, as follows.

[0096] Mix 6.2 kg of gypsum, 0.2 kg of flame retardant, and 0.5 kg of attapulgite clay at 1200 rpm for 3 min; add 15 g of retarder and 1.55 kg of water, and simultaneously inject 30 g of foaming agent; add 1.0 kg of composite fiber (where basalt fiber accounts for 65 wt%, and regenerated cellulose fiber accounts for 35 wt%), 0.3 kg of silica sol; use vacuum vibration molding (vacuum degree -0.08 MPa, vibration frequency 50 Hz), the initial setting time is 15 min; cure at 40°C / RH70% for 2 h; dry with hot air circulation at 60°C; apply a pressure of 0.5 MPa with a roller press for surface densification. A fiber-reinforced gypsum board is prepared.

[0097] Example 12

[0098] This example is used to prepare a fiber-reinforced gypsum board, as follows.

[0099] Mix 6.2 kg of gypsum, 0.2 kg of flame retardant, and 0.7 kg of attapulgite clay at 1200 rpm for 3 min; add 15 g of retarder and 1.55 kg of water, and simultaneously inject 30 g of foaming agent; add 1.0 kg of composite fiber (where basalt fiber accounts for 65 wt%, and regenerated cellulose fiber accounts for 35 wt%), 0.3 kg of silica sol; use vacuum vibration molding (vacuum degree -0.08 MPa, vibration frequency 50 Hz), the initial setting time is 15 min; cure at 40°C / RH70% for 2 h; dry with hot air circulation at 60°C; apply a pressure of 0.5 MPa with a roller press for surface densification. A fiber-reinforced gypsum board is prepared.

[0100] Example 13

[0101] This example is used to prepare a fiber-reinforced gypsum board, as follows.

[0102] Mix 6.2 kg of gypsum, 0.2 kg of flame retardant, and 0.8 kg of attapulgite clay at 1200 rpm for 3 min; add 15 g of retarder and 1.55 kg of water, and simultaneously inject 30 g of foaming agent; add 1.0 kg of composite fiber (where basalt fiber accounts for 65 wt%, and regenerated cellulose fiber accounts for 35 wt%), 0.3 kg of silica sol; use vacuum vibration molding (vacuum degree -0.08 MPa, vibration frequency 50 Hz), the initial setting time is 15 min; cure at 40°C / RH70% for 2 h; dry with 60°C hot air circulation; apply a pressure of 0.5 MPa with a roller press for surface densification. A fiber-reinforced gypsum board is prepared.

[0103] Perform performance tests on the gypsum boards prepared in Examples 10 to 13 above, and the results are shown in Table 3 (where the weight ratio is the weight ratio of the composite fiber to the attapulgite clay).

[0104] Table 3

[0105]

[0106] It can be seen from Examples 6 to 9 and Table 2, as well as Examples 10 to 13 and Table 3, that in the technical solution of this application, when the weight ratio of the addition amount of the composite fiber to the addition amount of the attapulgite clay is between 1.6 and 2.2, the flexural strength is stronger, the thermal conductivity is lower, especially the moisture-induced deformation rate is significantly decreased compared with other examples, and the fire resistance limit is increased by one grade compared with other examples; the comprehensive performance is better.

[0107] The above are all the preferred embodiments of this application. The protection scope of this application is not limited by this. Therefore, all equivalent changes made according to the structure, shape, and principle of this application should be covered within the protection scope of this application.

Claims

1. A fiber-reinforced gypsum board, characterized in that: The composition comprises the following components by weight: 58-68 parts of gypsum; Composite fiber 8-12 parts; 4-8 parts of attapulgite; 3-5 parts of silica sol; 0.2-0.5 parts of foaming agent; Retarder 0.12-0.18 parts; Flame retardant 1.8-2.5 parts; 15-18 parts water; In the composite fiber, basalt fiber accounts for 50-70wt% and regenerated cellulose fiber accounts for 30-50wt%.

2. The gypsum board according to claim 1, characterized in that The weight ratio of the composite fiber to attapulgite is 1.6-2.2:

1.

3. The gypsum board according to claim 1, characterized in that In the composite fiber, basalt fiber accounts for 65wt% and regenerated cellulose fiber accounts for 35wt%.

4. The gypsum board according to claim 1, characterized in that The particle size of the attapulgite is 2 to 200 μm.

5. The gypsum board according to claim 1, characterized in that The particle size of the silica sol is 20 to 50 nm.

6. The gypsum board according to claim 1, characterized in that The foaming agent is a protein-based foaming agent; And / or, the retarder is trisodium citrate; And / or, the flame retardant is a zinc borate + magnesium hydroxide composite system flame retardant.

7. A method for preparing a gypsum board according to claim 1, characterized in that: The following steps are involved: S1. Fiber pretreatment Basalt fiber: surface treatment with silane coupling agent and ethanol solution; Regenerated cellulose fiber: surface treated with 2% NaOH solution; S2. Slurry preparation 2.

1. Dry mixing stage: mixing gypsum, flame retardant and attapulgite; 2.2, Wet mixing stage: add retarder and water, and inject foaming agent simultaneously; 2.

3. Fiber incorporation: basalt fiber and regenerated cellulose fiber treated in S1, and silica sol are added in sequence. S3, tape casting Vacuum vibration molding is adopted, and the initial setting time is 12 to 15 minutes; S4, gradient drying Carry out curing treatment and then drying treatment; S5. Post-processing The roller press applies pressure for surface densification.

8. The preparation method according to claim 7, characterized in that: In S2, the stirring speed is 1200 rpm and the stirring time is 3 min.

9. The preparation method according to claim 7, characterized in that: In S4, the curing treatment is: curing at 40°C / RH70% for 2h; And / or, the drying treatment is: 60°C hot air circulation drying.

10. The preparation method according to claim 7, characterized in that: In S5, the pressure applied by the roller press is 0.5 MPa.

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