Gypsum plaster board and preparation method thereof

Abstract

The invention discloses a gypsum plaster board and a preparation method thereof, the gypsum plaster board comprises a base board layer, a gypsum core layer, heat insulation fireproof layers, a waterproof layer and a wear-resistant layer, the heat insulation fireproof layers are laid on the upper and lower surfaces of the gypsum core layer, the waterproof layer is laid on the heat insulation waterproof layer, and the wear-resistant layer is laid outside the waterproof layer; the base plate layer is composed of upper surface protection paper and lower surface protection paper, and the upper surface protection paper and the lower surface protection paper are both modified fiber paper. The surface protection paper has the beneficial effects that through the multi-layer structural design, the strength and the waterproof performance of the surface protection paper are improved through the modified fiber paper of the base plate layer; a plurality of raw materials and glass fiber chopped strands are added into the gypsum core layer, so that the strength, the waterproofness and the integrity of the core layer are enhanced; the cavities of the heat-insulation fireproof layer and the filling medium effectively improve the fireproof and heat-insulation capabilities of the board; the polyurethane film of the waterproof layer and the fireproof rubber plate of the wear-resistant layer respectively provide reliable waterproof and wear-resistant protection, and tight combination and stable performance of the layers of the plate are ensured.

Description

Technical Field

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

[0002] As a commonly used building decoration material, the paper-faced gypsum board has the advantages of light weight, high strength, and convenient processing, and is widely used in indoor partition walls, ceilings and other fields.

[0003] 1. As disclosed in a Chinese patent for a paper-faced gypsum board and a preparation method thereof (Publication No.: CN114920535B). The paper-faced gypsum board includes the following components by weight: 60-70 parts of desulfurized gypsum, 5-15 parts of basalt fiber, 1-5 parts of sepiolite fiber, 5-10 parts of modified starch, 3-7 parts of modified APAO emulsion, 0.1-0.5 parts of composite foaming agent, 0.03-0.05 parts of retarder, 0.1-0.5 parts of water reducing agent, 50-75 parts of water, and facing paper. The prepared gypsum board has the properties of high strength, high toughness and water resistance, and there is no opening on the paper surface during transportation under long-term high temperature or low temperature (extreme temperature) conditions.

[0004] 2. A paper-faced gypsum board and a preparation method thereof (Publication No.: CN113429185B), the paper-faced gypsum board includes a board core and facing paper, and the board core includes dihydrate gypsum, aerogel particles and a binder obtained by hydrating gypsum clinker; the aerogel particles are aerogel particles formed by granulating aerogel and sodium silicate. This application uses a special process to add aerogel to the gypsum board, which improves the heat preservation function of the product while not affecting the mechanical properties and bonding properties, and has wide application value.

[0005] However, the existing paper-faced gypsum boards still have certain deficiencies in fire resistance, heat insulation, waterproof and wear resistance. For example, the fire and heat insulation ability of the traditional gypsum core layer is limited, and it is easy to lose strength in a high-temperature environment; the waterproof performance of the surface facing paper is not good, and it is easy to get damp and deformed in a long-term humid environment; in addition, the wear resistance of the surface wear-resistant layer is insufficient, resulting in a short service life of the board.

[0006] Therefore, it is necessary to propose a paper-faced gypsum board and a preparation method thereof for the above technical solutions. Summary of the Invention

[0007] The purpose of the present invention is to provide a paper-faced gypsum board and a preparation method thereof.

[0008] To achieve the above purpose, the present invention provides the following technical solutions:

[0009] A paper-faced gypsum board includes a base board layer, a gypsum core layer, a heat-insulating and fireproof layer, a waterproof layer and a wear-resistant layer. The heat-insulating and fireproof layer is laid on the upper and lower surfaces of the gypsum core layer. The waterproof layer is laid on the heat-insulating and waterproof layer. The base board layer is laid outside the waterproof layer. The wear-resistant layer is laid outside the base board layer;

[0010] The base board layer is composed of an upper facing paper and a lower facing paper. Both the upper facing paper and the lower facing paper are modified fiber papers. 5%-10% of glass fiber and 3%-5% of waterproof agent are added to the modified fiber paper. By weight, the gypsum core layer includes the following raw materials: 100 parts of desulfurized gypsum, 10-15 parts of cement, 5-10 parts of fly ash, 2-5 parts of short glass fiber filaments, 0.3-0.5 parts of hydroxypropyl methylcellulose, 0.1-0.3 parts of starch ether, 1-2 parts of waterproof agent, 0.5-1 part of water-reducing agent, and 60-80 parts of water.

[0011] Preferably, the heat-insulating and fireproof layer is provided with cavities, and the cavities are filled with water or fireproof and flame-retardant liquid.

[0012] Preferably, the waterproof layer adopts a polyurethane film.

[0013] Preferably, the waterproof agent is calcium stearate or silicone waterproof agent.

[0014] Preferably, the length of the short glass fiber filaments is 3-5 mm.

[0015] Preferably, the wear-resistant layer adopts a fireproof rubber plate.

[0016] Preferably, the fireproof and flame-retardant liquid adopts phosphate ester or ammonium polyphosphate.

[0017] A preparation method of the paper-faced gypsum board includes the following steps:

[0018] S1. Raw material pretreatment: Crush the desulfurized gypsum and pass it through a 200-mesh sieve, and process the short glass fiber filaments to a length of 3-5 mm;

[0019] S2. Preparation of gypsum slurry: Dry-mix the desulfurized gypsum, cement, fly ash, hydroxypropyl methylcellulose, starch ether, waterproof agent and water-reducing agent, then add water and stir, and finally add the short glass fiber filaments and continue to stir;

[0020] S3. Forming process: Lay the upper facing paper on the conveyor belt, lay the gypsum slurry and then cover it with the lower facing paper, and pre-press it by a roll press to obtain a preliminarily formed board;

[0021] S4. Static curing: Cure the preliminarily formed board at a temperature of 40-50 °C and a humidity of 60%-70% for 2-3 hours;

[0022] S5. Drying treatment: A three-stage drying process is adopted to reduce the moisture content of the board to less than 5%.

[0023] S6. Surface treatment: The dried board is sanded to obtain the finished product.

[0024] Preferably, the pre-pressing pressure of the roll press is 0.3 - 0.5 MPa.

[0025] Preferably, the parameters of the three-stage drying process are: the temperature of the first stage is 60 - 70 °C, and the time is 1 - 2 hours; the temperature of the second stage is 80 - 90 °C, and the time is 2 - 3 hours; the temperature of the third stage is 100 - 110 °C, and the time is 1 - 2 hours.

[0026] Compared with the prior art, the beneficial effects of the present invention are as follows: Through the multi-layer structure design of the present invention, the modified fiber paper of the substrate layer improves the strength and waterproof performance of the facing paper; a variety of raw materials and short glass fiber filaments added in the gypsum core layer enhance the strength, waterproofness and integrity of the core layer; the cavity and filling medium of the heat insulation and fireproof layer effectively improve the fireproof and heat insulation ability of the board; the polyurethane film of the waterproof layer and the fireproof rubber plate of the wear-resistant layer respectively provide reliable waterproof and wear-resistant protection. The optimization of each process parameter in the preparation method ensures the tight combination and stable performance between the layers of the board. The gypsum board with paper surface of the present invention has various excellent properties such as fireproof, waterproof, heat insulation and wear resistance, and is suitable for places with high requirements for the performance of building materials. Description of the Drawings

[0027] Figure 1 It is a schematic structural diagram of the gypsum board with paper surface of the present invention;

[0028] Figure 2 It is a structural diagram of the substrate layer of the present invention;

[0029] Figure 3 It is a structural diagram of the heat insulation and fireproof layer of the present invention;

[0030] Figure 4 It is a flow chart of the preparation method of the present invention.

[0031] Reference numerals in the drawings: 1. Substrate layer; 2. Gypsum core layer; 3. Heat insulation and fireproof layer; 4. Waterproof layer; 5. Wear-resistant layer; 6. Upper facing paper; 7. Lower facing paper; 8. Cavity. Detailed Embodiments

[0032] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0033] As Figures 1 to 4 shown, a gypsum plasterboard includes a base board layer 1, a gypsum core layer 2, a heat insulation and fireproof layer 3, a waterproof layer 4 and a wear-resistant layer 5. The heat insulation and fireproof layer 3 is laid on the upper and lower surfaces of the gypsum core layer 2. The waterproof layer 4 is laid on the heat insulation and waterproof layer 3. The base board layer 1 is paved outside the waterproof layer 4. The wear-resistant layer 5 is laid outside the base board layer 1;

[0034] The base board layer 1 is composed of an upper facing paper 6 and a lower facing paper 7. Both the upper facing paper 6 and the lower facing paper 7 are modified fiber papers. Glass fibers accounting for 5%-10% of the paper mass and a waterproofing agent accounting for 3%-5% are added to the modified fiber papers. The gypsum core layer 2, by weight, comprises the following raw materials: 100 parts of desulfurized gypsum, 10-15 parts of cement, 5-10 parts of fly ash, 2-5 parts of short cut glass fibers, 0.3-0.5 parts of hydroxypropyl methyl cellulose, 0.1-0.3 parts of starch ether, 1-2 parts of waterproofing agent, 0.5-1 part of water reducing agent, and 60-80 parts of water.

[0035] Further, the heat insulation and fireproof layer 3 is provided with a cavity 8, and the cavity 8 is filled with water or a fireproof and flame retardant liquid. The heat insulation and fireproof layer 3 is provided with the cavity 8 and filled with water or a fireproof and flame retardant liquid. This design enables the water or the fireproof and flame retardant liquid to absorb heat to reduce the temperature of the board and block heat transfer during a fire, greatly enhancing the fireproof and heat insulation performance of the gypsum plasterboard and providing guarantee for building fire safety.

[0036] Further, the waterproof layer 4 uses a polyurethane film. The use of the polyurethane film, which has excellent waterproof performance and flexibility, can closely adhere to the heat insulation and fireproof layer to form a continuous and dense waterproof barrier, effectively preventing moisture from invading the interior of the board and avoiding problems such as deformation and damage caused by moisture, thus extending the service life of the gypsum plasterboard.

[0037] Further, the waterproofing agent is calcium stearate or silicone waterproofing agent. These two waterproofing agents can form a waterproof film or change the surface tension in the paper and the gypsum core layer 2, effectively preventing moisture penetration, and significantly enhancing the waterproof performance of both the base board layer 1 and the gypsum core layer 2.

[0038] Further, the length of the short cut glass fibers is 3-5 mm. This length can be evenly dispersed in the gypsum core layer 2, fully exerting the strengthening effect, effectively improving the strength and crack resistance of the core layer, making the gypsum plasterboard not easily crack when subjected to external forces or environmental changes, and ensuring the integrity and stability of the board.

[0039] Furthermore, the wear-resistant layer 5 is made of a fireproof rubber sheet. The fireproof rubber sheet not only has fireproof performance but also can effectively resist friction and wear, protecting the surface of the board. During daily use, even if it is frequently rubbed, it can keep the surface intact, improving the durability and aesthetics of the gypsum board.

[0040] Furthermore, the fireproof and flame-retardant liquid is made of phosphate ester or ammonium polyphosphate. These two substances will decompose to form a covering layer when heated, isolating oxygen, blocking heat transfer, and promoting carbonization on the surface of the material, thus efficiently inhibiting combustion and further strengthening the fireproof and flame-retardant effect of the heat-insulating and fireproof layer, improving the fire safety level of the gypsum board.

[0041] A preparation method of a gypsum board includes the following steps:

[0042] S1. Raw material pretreatment: Crush the desulfurized gypsum and then sieve it through a 200-mesh sieve, and process the short glass fiber filaments to a length of 3 - 5 mm;

[0043] S2. Preparation of gypsum slurry: Dry-mix the desulfurized gypsum, cement, fly ash, hydroxypropyl methylcellulose, starch ether, waterproof agent, and water reducer, then add water and stir, and finally add the short glass fiber filaments and continue to stir;

[0044] S3. Forming process: Lay the upper facing paper on the conveyor belt, lay the gypsum slurry and then cover it with the lower facing paper, and obtain a preliminarily formed board through pre-pressing by a roll press;

[0045] S4. Static curing: Cure the preliminarily formed board at a temperature of 40 - 50 °C and a humidity of 60% - 70% for 2 - 3 hours;

[0046] S5. Drying treatment: Adopt a three-stage drying process to reduce the moisture content of the board to less than 5%;

[0047] S6. Surface treatment: Sand the dried board to obtain the finished product.

[0048] Preferably, the pre-pressing pressure of the roll press is 0.3 - 0.5 MPa. Within this pressure range, it can ensure the tight combination of the facing paper and the gypsum core layer, enabling the board to have good structural strength at the initial forming stage, avoiding problems such as loose bonding caused by insufficient pressure or deformation and damage of the board caused by excessive pressure, and ensuring the forming quality of the product.

[0049] Further, the parameters of the three-stage drying process are as follows: the temperature in the first stage is 60 - 70°C, and the time is 1 - 2 hours; the temperature in the second stage is 80 - 90°C, and the time is 2 - 3 hours; the temperature in the third stage is 100 - 110°C, and the time is 1 - 2 hours. The low-temperature drying in the first stage allows the moisture inside the board to evaporate slowly, avoiding cracking caused by the rapid drying of the surface while the internal moisture cannot be discharged. The temperature is gradually increased in the second and third stages to further dry the board and ensure that the moisture content is reduced to less than 5%. This gradual drying method effectively guarantees the drying quality and dimensional stability of the board and improves the qualified rate of the product.

[0050] Compared with the prior art, the beneficial effects of the present invention are as follows: Through the multi-layer structure design, the modified fiber paper in the base board layer improves the strength and waterproof performance of the facing paper; the various raw materials and chopped glass fiber filaments added in the gypsum core layer 2 enhance the strength, waterproofness and integrity of the core layer; the cavities and filling media in the heat insulation and fireproof layer effectively improve the fireproof and heat insulation ability of the board; the polyurethane film in the waterproof layer and the fireproof rubber board in the wear-resistant layer respectively provide reliable waterproof and wear-resistant protection. The optimization of the process parameters in the preparation method ensures the tight combination and stable performance between the layers of the board. Overall, the gypsum board with paper facing of the present invention has various excellent properties such as fireproof, waterproof, heat insulation and wear resistance, and is suitable for places with high requirements for the performance of building materials.

[0051] Example 1:

[0052] Raw material composition of gypsum board with paper facing

[0053] Base board layer 1: The addition amount of glass fiber in the modified fiber paper is 5% of the paper quality, and the addition amount of waterproof agent (calcium stearate) is 3%.

[0054] Gypsum core layer 2: By weight, 100 parts of desulfurized gypsum, 10 parts of cement, 5 parts of fly ash, 2 parts of chopped glass fiber filaments (length 3mm), 0.3 part of hydroxypropyl methylcellulose, 0.1 part of starch ether, 1 part of waterproof agent (calcium stearate), 0.5 part of water reducing agent, and 60 parts of water.

[0055] Heat insulation and fireproof layer 3: The cavity is filled with phosphate fire retardant liquid.

[0056] Waterproof layer 4: Polyurethane film.

[0057] Wear-resistant layer 5: Fireproof rubber board.

[0058] Preparation method

[0059] Raw material pretreatment: The desulfurized gypsum is crushed and then passed through a 200-mesh sieve, and the chopped glass fiber filaments are processed to 3mm.

[0060] Preparation of gypsum slurry: Mix the dry materials and then add water and stir, and finally add the chopped glass fiber filaments and continue to stir.

[0061] Forming process: The pre-pressing pressure is 0.3 MPa to form a preliminarily formed board.

[0062] Static curing: Curing for 2 hours under the conditions of 40 °C and 60% humidity.

[0063] Drying treatment: The first stage is at 60 °C for 1 hour; the second stage is at 80 °C for 2 hours; the third stage is at 100 °C for 1 hour, and the moisture content is reduced to less than 5%.

[0064] Surface treatment: Obtain the finished product by sanding treatment.

[0065] Example 2

[0066] Raw material composition of gypsum board

[0067] Base board layer 1: The addition amount of glass fiber in the modified fiber paper is 10% of the paper quality, and the addition amount of waterproof agent (organosilicon waterproof agent) is 5%.

[0068] Gypsum core layer 2: By weight, 100 parts of desulfurized gypsum, 15 parts of cement, 10 parts of fly ash, 5 parts of short cut glass fiber (length 5 mm), 0.5 part of hydroxypropyl methyl cellulose, 0.3 part of starch ether, 2 parts of waterproof agent (organosilicon waterproof agent), 1 part of water reducing agent, and 80 parts of water.

[0069] Heat insulation and fireproof layer 3: The cavity is filled with ammonium polyphosphate fire retardant liquid.

[0070] Waterproof layer 4: Polyurethane film.

[0071] Wear-resistant layer 5: Fireproof rubber board.

[0072] Preparation method

[0073] Raw material pretreatment: Crush the desulfurized gypsum and sieve it through a 200-mesh sieve, and process the short cut glass fiber to 5 mm.

[0074] Preparation of gypsum slurry: Mix the dry materials and add water to stir, and finally add the short cut glass fiber and continue to stir.

[0075] Forming process: The pre-pressing pressure is 0.5 MPa to form a preliminarily formed board.

[0076] Static curing: Curing for 3 hours under the conditions of 50 °C and 70% humidity.

[0077] Drying treatment: The first stage is at 70 °C for 2 hours; the second stage is at 90 °C for 3 hours; the third stage is at 110 °C for 2 hours, and the moisture content is reduced to less than 5%.

[0078] Surface treatment: Obtain the finished product by sanding treatment.

[0079] The gypsum board produced through the above-mentioned embodiments, after testing, has a fire resistance rating of B1, a water absorption rate lower than 5%, and the surface abrasion resistance exceeds 5000 times. All performance indicators are superior to traditional gypsum boards, meeting the usage requirements of high-end building decoration materials.

[0080] Comparison analysis table of embodiments 1:

[0081]

[0082] Comparative analysis: The increase in glass fiber content improves the tear resistance of the base board layer; the silicone waterproofing agent has stronger permeability and better waterproof effect in the core layer; the high content of long fibers and high cement dosage significantly improves the compressive strength of the core layer (by 30%) and crack resistance (cracks reduced by 60%); ammonium polyphosphate forms a dense carbonized layer at high temperatures, extending the fire protection time by 20% (up to 60 minutes); high pressure makes the facing paper and the core layer bond more tightly (the peel strength increases from 15 N / cm to 25 N / cm); deep drying reduces the internal residual moisture and improves the dimensional stability (the moisture-induced deformation rate decreases from 0.8% to 0.5%); all reach the non-combustible level, and the carbonized layer of embodiment 2 is thicker, delaying heat transfer; the combination of silicone waterproofing agent and high-pressure forming reduces the porosity of the core layer and improves the waterproof performance.

[0083] The modified fiber paper in the base board layer 1 and the waterproofing agent in the core layer form a double waterproof barrier, reducing the water absorption rate by more than 60% compared to traditional boards;

[0084] The cavity filling liquid in the heat insulation and fire protection layer 3 absorbs heat through phase change (vaporization of water / flame retardant liquid), reducing the temperature on the back fire side of the board by 30°C - 50°C.

[0085] The utilization rate of industrial solid wastes such as desulfurized gypsum and fly ash reaches more than 90%, and there is no formaldehyde release during the production process;

[0086] Both the polyurethane film and the fireproof rubber board use environmentally friendly adhesives, meeting the formaldehyde limit standard of GB 18580.

[0087] Processing adaptability: The two-stage drying process avoids cracking of the board (the cracking rate of the traditional process is about 5%, and that of the present invention is <1%); the standard size (1200mm×2400mm) is suitable for automatic cutting equipment, reducing the processing loss rate to 3%.

[0088] By adjusting the raw material ratio and process parameters, the above-mentioned embodiments can be flexibly adapted to different scenarios such as residential, commercial, and public buildings, achieving differential optimization in terms of fire protection, waterproofing, abrasion resistance, etc.

[0089] Although embodiments of the present invention have been shown and described, it will be understood by those of ordinary skill in the art that various changes, modifications, substitutions and variations can be made to these embodiments without departing from the principles and spirit of the present invention, and the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A paper-faced gypsum board, characterized in that: It includes a substrate layer (1), a gypsum core layer (2), a heat-insulating and fireproof layer (3), a waterproof layer (4) and a wear-resistant layer (5). The heat-insulating and fireproof layer (3) is laid on the upper and lower surfaces of the gypsum core layer (2). The waterproof layer (4) is laid on the heat-insulating and waterproof layer (3). The substrate layer (1) is paved outside the waterproof layer (4). The wear-resistant layer (5) is laid outside the substrate layer (1). The substrate layer (1) is composed of an upper facing paper (6) and a lower facing paper (7). Both the upper facing paper (6) and the lower facing paper (7) are modified fiber papers. Glass fibers accounting for 5%-10% of the paper mass and a waterproofing agent accounting for 3%-5% of the paper mass are added to the modified fiber papers. By weight, the gypsum core layer (2) includes the following raw materials: 100 parts of desulfurized gypsum, 10-15 parts of cement, 5-10 parts of fly ash, 2-5 parts of short glass fiber filaments, 0.3-0.5 parts of hydroxypropyl methylcellulose, 0.1-0.3 parts of starch ether, 1-2 parts of waterproofing agent, 0.5-1 part of water reducing agent, and 60-80 parts of water.

2. The gypsum plasterboard according to claim 1, wherein: The heat-insulating and fireproof layer (3) is provided with cavities (8), and the cavities (8) are filled with water or a fireproof and flame-retardant liquid.

3. A paper-faced gypsum board according to claim 1, characterized in that: The waterproof layer (4) uses a polyurethane film.

4. A gypsum plasterboard as claimed in claim 1, wherein: The waterproofing agent is calcium stearate or an organosilicon waterproofing agent.

5. A paper-faced gypsum board according to claim 1, characterized in that: The length of the short glass fiber filaments is 3-5 mm.

6. A gypsum plasterboard as claimed in claim 1, wherein: The wear-resistant layer (5) uses a fireproof rubber plate.

7. A gypsum plasterboard as claimed in claim 2, wherein: The fireproof and flame-retardant liquid uses phosphate ester or ammonium polyphosphate.

8. A method for preparing a paper-faced gypsum board according to any one of claims 1-7, characterized in that, It includes the following steps: S1. Raw material pretreatment: Crush the desulfurized gypsum and pass it through a 200-mesh sieve, and process the short glass fiber filaments to a length of 3-5 mm. S2. Preparation of gypsum slurry: Dry-mix the desulfurized gypsum, cement, fly ash, hydroxypropyl methylcellulose, starch ether, waterproofing agent and water reducing agent, then add water and stir, and finally add the short glass fiber filaments and continue to stir. S3. Forming process: Lay the upper facing paper on the conveyor belt, lay the gypsum slurry and then cover it with the lower facing paper, and pre-press it with a roll press to obtain a preliminarily formed board. S4. Static curing: Cure the preliminarily formed board at a temperature of 40-50 °C and a humidity of 60%-70% for 2-3 hours. S5. Drying treatment: Adopt a three-stage drying process to reduce the moisture content of the board to less than 5%. S6. Surface treatment: Sand the dried board to obtain the finished product.

9. The method for preparing a paper-faced gypsum board according to claim 8, characterized in that, The pre-pressing pressure of the roll press is 0.3-0.5 MPa.

10. A method for preparing a paper-faced gypsum board according to claim 8, characterized in that, The parameters of the three-stage drying process are: the first stage temperature is 60-70 °C and the time is 1-2 hours; the second stage temperature is 80-90 °C and the time is 2-3 hours; the third stage temperature is 100-110 °C and the time is 1-2 hours.

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