Reinforced and toughened composite mineral board and preparation process thereof

Abstract

The invention relates to the field of building materials, in particular to a reinforced and toughened composite mineral board and a preparation process thereof. A reinforced and toughened composite mineral board comprises a base material layer, a decorative layer located on the base material layer and a reinforcing layer located below the base material layer. According to the preparation technology of the reinforced and toughened composite mineral board, the problems that due to limitation of mineral boards and the influence of stress, environment and the like on the boards, the boards are prone to deformation in use, the binding force in base materials is not strong, and the structure is loose are solved; the prepared composite mineral board has the advantages of being good in toughness, high in strength and not prone to cracking.

Description

Technical Field

[0001] The present application relates to the field of building materials, and more specifically, to a reinforced and toughened composite mineral plate and a preparation process thereof. Background Art

[0002] With the improvement of people's living standards, the requirements for the environmental protection, flame retardancy, beauty, etc. of composite board decorative materials are getting higher and higher. As the main structural layer of the composite board, the physical and mechanical properties of the substrate are extremely important for the application of the composite board. At present, most of the substrates are made of wood substrates with decorative paper or paint finishes, seriously lacking fire resistance, water resistance, corrosion resistance, environmental protection and material firmness. Moreover, the price of wood substrates in the current market is constantly rising, and the lack of resources is becoming more and more serious, resulting in the continuous increase of the production cost of wood substrates.

[0003] Mineral plates are a novel decorative material, and their advantages such as stability, flame retardancy, no formaldehyde, and low cost are increasingly meeting the market demand. However, the known mineral plates are mostly formed by the reaction and crystallization of inorganic materials under high temperature and high pressure, so they are essentially crystalline powders of many inorganic mineral materials. Due to the weak binding force between the powders, when a surface material is to be attached to the surface of such mineral plates, the powders closer to the surface material are easily torn up and peeled off by the surface material, making it difficult for the surface material to be firmly attached, that is, the surface material is quite easy to be peeled off. After careful investigation, the reason is that the mineral plates themselves are affected by stress, with a loose structure, low binding force strength between the powders, and low adhesiveness, resulting in the slow shedding of the mineral powders; and after the mineral plates are divided into small pieces, they are also prone to side bending. Due to the poor toughness of the mineral plates themselves, they are extremely easy to crack after being bent, which is actually a difficult point in construction. Summary of the Invention

[0004] Aiming at the limitations of mineral plates, the problems that the substrate itself is affected by stress and the environment, resulting in easy deformation of the plate during use, weak binding force inside the substrate, and loose structure, the present application provides a preparation process for a reinforced and toughened composite mineral plate, so that the prepared composite mineral plate has the advantages of good toughness, high strength, and not easy to crack.

[0005] In the first aspect, the present application provides a preparation process for a reinforced and toughened composite mineral plate, adopting the following technical solutions: A reinforced and toughened composite mineral plate, which includes a substrate layer, a decorative layer on the substrate layer, and a reinforcing layer under the substrate layer.

[0006] By using the decorative layer and the reinforcing layer, which are arranged on the upper and lower surfaces of the substrate layer, the compressive strength and internal bonding strength of the mineral plate are effectively improved, and the surface material is prevented from being peeled off.

[0007] In a specific feasible embodiment, the substrate layer comprises the following components in parts by weight: 28 - 45 parts of light-burned magnesium oxide powder, 18 - 22 parts of magnesium sulfate heptahydrate, 10 - 19 parts of polyvinyl alcohol solution, 16 - 18 parts of plant powder, and 0.5 - 1 part of modifier; the modifier is citric acid monohydrate: sodium sulfate: phosphoric acid; the fineness of the plant powder is 20 - 120 mesh.

[0008] By adopting the above technical solution, citric acid monohydrate, sodium sulfate, and phosphoric acid improve the stability of the magnesium board due to their excellent water solubility. Citric acid monohydrate is acidic and can adjust the pH value of the system; sodium sulfate has stable chemical properties and can enhance the structural stability; phosphoric acid can react with magnesium ions to form a protective film. The mixture of the three can also inhibit adverse chemical reactions, significantly improve the stability and corrosion resistance, and greatly extend the service life of the magnesium board substrate.

[0009] In a specific feasible embodiment, the reinforcing layer is formed by hot pressing a melamine impregnated paper and a wood veneer with a thickness of 0.3 - 3 mm. 2 The decorative layer is formed by hot pressing a melamine pattern paper and a wood veneer with a thickness of 0.5 - 1 mm.

[0010] An aluminum oxide layer is also provided on the decorative layer.

[0011] By using a melamine impregnated paper and a wood veneer, hot pressing is carried out under high temperature and high pressure to form the reinforcing layer; an aluminum oxide layer is provided on the decorative layer on the upper surface of the substrate layer as an abrasion-resistant layer, so as to improve the abrasion resistance and water resistance of the composite mineral board, and further enhance the mechanical properties and environmental protection of the composite mineral board.

[0012] In a specific feasible embodiment, the reinforcing layer comprises a base layer with a structure of 6 - 8 layers of thermoplastic spunbonded fabric layers adhesively bonded in a transverse-longitudinal alternating manner, and a melamine impregnated paper is adhered to one transverse side of the base layer. The decorative layer comprises a base layer with a structure of 6 - 8 layers of thermoplastic spunbonded fabric layers adhesively bonded in a transverse-longitudinal alternating manner, and a melamine impregnated pattern paper is adhered to one longitudinal side of the base layer.

[0013] The adhesive bonding is carried out through a binder, and the binder is one or several of waterborne acrylic acid, polyurethane, and polyvinyl alcohol.

[0014] The thermoplastic spunbonded fabric is one or two of PET and PA.

[0015]

[0016] ​By adopting the above technical solutions: The reinforcing layer and the decorative layer adopt a thermoplastic blended fabric layer structure with multi-layer horizontal and vertical alternating adhesives. The unique staggered laying can make the stress distribution uniform among the layers. When subjected to complex external stresses, the horizontal and vertical fabric layers restrain each other, effectively resisting external forces such as bending, stretching, and compression, greatly enhancing the overall structural stability and reducing the possibility of deformation and damage. The thermoplastic blended fabric itself has a certain strength and toughness, and the multi-layer staggered structure further strengthens this property. When subjected to external impact, each layer cooperates with each other to disperse and absorb energy synergistically, avoiding local damage caused by stress concentration, and significantly improving the overall strength and toughness. The decorative layer is longitudinally bonded with a melamine-impregnated patterned paper, which not only brings rich decorative effects to meet diverse aesthetic needs, but also effectively resists scratching, stains, and chemical erosion, protecting the internal structure. And it makes the reinforcing layer waterproof, moisture-proof, and high in hardness. Furthermore, it enhances the peel strength and toughness of the substrate layer, enabling the entire structure to function stably in different application scenarios, reducing the risk of damage, and extending the service life.

[0017] In the second aspect, the present application provides a preparation process for an enhanced and toughened composite mineral plate, adopting the following technical solutions: A preparation process for an enhanced and toughened composite mineral plate includes the following steps: Evenly coat the upper and lower surfaces of the substrate layer with a two-component polyurethane adhesive, and then cold-press and bond it with the decorative layer and the reinforcing layer, so that the wood fiber directions of the decorative layer and the reinforcing layer are the same and staggered with the direction of the substrate layer. After curing, cut and trim the edges to obtain the enhanced and toughened composite mineral plate.

[0018] In the S1 step, the hot-pressing temperature is 130 - 210 °C, the pressure is 5 - 20 Mpa, and the time is 10 - 30 min.

[0019] In the S3 step, the pressure for cold-press bonding is 5 - 20 Mpa.

[0020] By preparing a substrate layer mainly made of minerals such as magnesium oxide, and bonding reinforcing layers on both the upper and lower surfaces through a two-component polyurethane adhesive coated on the upper and lower surfaces, a sandwich structure is formed for the substrate layer, improving the strength and toughness of the entire composite mineral plate. The process of the present application first performs hot pressing, and makes the wood fiber directions of the upper and lower reinforcing layers the same, so that the reinforcing layer and the middle substrate layer both have a certain static friction force, improving the interfacial bonding ability between the layers of the plate, enhancing the internal bonding strength and peel strength, and making the direction of the substrate layer staggered with the directions of the upper and lower surface reinforcing layers, and the directions of the upper and lower reinforcing layers are the same. The purpose is to form restrictions on the substrate layer by the upper and lower surfaces after staggering with the substrate layer, which can effectively control material deformation, displacement, and dimensional changes, and to a certain extent improve the limitation of easy deformation during pressing in the production process of magnesium oxide boards.

[0021] In summary, the present application has the following beneficial effects: 1. By applying a two-component polyurethane adhesive to the upper and lower surfaces of the base material layer, reinforcing layers are bonded to both the upper and lower surfaces, forming a sandwich structure for the base material layer, thereby improving the strength and toughness of the entire composite mineral plate. 2. The reinforcing layer and the decorative layer adopt a thermoplastic spunbonded fabric layer structure with multi-layer transverse and longitudinal alternating adhesives. The unique staggered laying can make the stress distribution uniform among the layers. When subjected to complex external stresses, the transverse and longitudinal fabric layers restrain each other, effectively resisting external forces such as bending, stretching, and compression, greatly enhancing the overall structural stability and reducing the possibility of deformation and damage. The thermoplastic spunbonded fabric itself has certain strength and toughness, and the multi-layer staggered structure further enhances this property. When subjected to external impact, the layers cooperate with each other to jointly disperse and absorb energy, avoiding local damage caused by stress concentration, and significantly improving the overall strength and toughness. The decorative layer is longitudinally bonded with a melamine-impregnated pattern paper, which not only brings rich decorative effects to meet diverse aesthetic needs, but also effectively resists scratching, stains, and chemical erosion, protecting the internal structure. And it makes the reinforcing layer waterproof, moisture-proof, and has high hardness. Furthermore, it enhances the peel strength and toughening of the base material layer, enabling the entire structure to function stably in different application scenarios, reducing the risk of damage, and extending the service life. Specific Embodiments

[0022] The present application will be further described in detail below with reference to the embodiments.

[0023] Some of the raw materials used in the preparation examples and the embodiments: Light-burned magnesia was purchased from: Shandong Heze Chemical Co., Ltd.; the polyvinyl alcohol solution was a polyvinyl alcohol solution with a mass concentration of 30%, purchased from Chaohu Desheng Chemical Construction Co., Ltd.; magnesium sulfate solution: a magnesium sulfate solution with a concentration of 15%, prepared by mixing crystalline magnesium sulfate heptahydrate with water, and the purity of magnesium sulfate heptahydrate was about 99.7%; the plant powder was selected as bamboo powder with a mesh size of 60; the two-component polyurethane adhesive model: N-PU 5801BF; the wood veneer was a 1-mm-thick black walnut artificial wood veneer with a moisture content of 25%; aluminum oxide was aluminum oxide with a wear resistance strength ≥ the AC4 standard in EN13329; melamine formaldehyde resin was purchased from Jinan Huijinchuan Chemical Co., Ltd.

[0024] For the related raw materials not specified in the embodiments and the comparative examples, they are all conventional products that can be obtained through the market.

[0025] Example 1 Reinforced and toughened composite mineral plate: It includes a base material layer, a decorative layer located on the base material layer, and a reinforcing layer under the base material layer; the reinforcing layer is formed by hot pressing melamine impregnated paper and a 3-mm-thick wood veneer, the decorative layer is formed by hot pressing melamine pattern paper and a 1-mm-thick wood veneer, and the base material layer includes the following components in parts by weight: 280 g of light-burned magnesium oxide, 220 g of magnesium sulfate solution, 100 g of polyvinyl alcohol solution, 160 g of plant powder, and 10 g of modifier. The modifier is citric acid monohydrate: sodium sulfate: phosphoric acid with a mass ratio of 9:2:6.

[0026] Preparation process of the reinforced and toughened composite mineral plate: According to the ratio, blend and stir the magnesium sulfate solution and the polyvinyl alcohol solution evenly, then add the light-burned magnesium oxide, plant powder, and modifier and blend them. Lay them and perform hot pressing. The hot pressing temperature is 180 °C, the pressure is 12 Mpa, and the time is 30 min to obtain the base material layer; for 80 g / m 2 Impregnate multiple layers of paper with resin. The resin for impregnation is melamine formaldehyde resin. The resin content of the impregnated multiple layers of paper is 80%. Then perform hot pressing with the wood veneer. The temperature is 135 °C, the pressure is 6 Mpa, and the hot pressing time is 20 min to form the reinforcing layer; repeat the above preparation method to make the decorative layer with melamine pattern paper and a 1-mm-thick wood veneer; evenly coat the upper and lower surfaces of the base material layer with two-component polyurethane adhesive, and then cold press and bond with the reinforcing layer and the decorative layer under a pressure of 17 Mpa, so that the wood fiber directions of the reinforcing layer and the decorative layer are the same and staggered with the direction of the base material layer. After curing, cut and trim the edges to obtain the reinforced and toughened composite mineral plate.

[0027] Example 2 Reinforced and toughened composite mineral plate: It includes a base material layer, a decorative layer located on the base material layer, and a reinforcing layer under the base material layer; the reinforcing layer is formed by hot pressing melamine impregnated paper and a 3-mm-thick wood veneer, the decorative layer is formed by hot pressing melamine pattern paper and a 1-mm-thick wood veneer, and the base material layer includes the following components in parts by weight: 350 g of light-burned magnesium oxide, 220 g of magnesium sulfate solution, 160 g of polyvinyl alcohol solution, 180 g of plant powder, and 7 g of modifier. The modifier is citric acid monohydrate: sodium sulfate: phosphoric acid with a mass ratio of 9:2:6.

[0028] Preparation process of the reinforced and toughened composite mineral plate: According to the ratio, blend and stir the magnesium sulfate solution and the polyvinyl alcohol solution evenly, then add the light-burned magnesium oxide, plant powder, and modifier and blend them. Lay them and perform hot pressing. The hot pressing temperature is 180 °C, the pressure is 12 Mpa, and the time is 30 min to obtain the base material layer; for 70 g / m 2The multi-layer paper is impregnated with a resin, and the impregnating resin is melamine formaldehyde resin. After impregnation, the resin content of the multi-layer paper is 100%. Then it is hot-pressed with wood veneer at a temperature of 135 °C, a pressure of 6 Mpa, and a hot-pressing time of 20 min to form a reinforcing layer. The above preparation method is repeated to make a decorative layer with melamine pattern paper and a 1-mm-thick wood veneer. The upper and lower surfaces of the base material layer are evenly coated with a two-component polyurethane adhesive, and then cold-pressed and bonded with the reinforcing layer and the decorative layer under a pressure of 17 Mpa, so that the wood fiber directions of the reinforcing layer and the decorative layer are the same and are staggered with the direction of the base material layer. After curing, it is cut and trimmed to obtain a reinforced and toughened composite mineral plate.

[0029] Example 3 Reinforced and toughened composite mineral plate: It includes a base material layer, a decorative layer on the base material layer, and a reinforcing layer under the base material layer; the reinforcing layer is formed by hot-pressing melamine-impregnated paper and a 3-mm-thick wood veneer, and the decorative layer is formed by hot-pressing melamine pattern paper and a 1-mm-thick wood veneer. The base material layer includes the following components in parts by weight: 280 g of light-burned magnesium oxide, 220 g of magnesium sulfate solution, 100 g of polyvinyl alcohol solution, 160 g of plant powder, and 10 g of modifier. The modifier is citric acid monohydrate: sodium sulfate: phosphoric acid with a mass ratio of 9:2:6.

[0030] Preparation process of the reinforced and toughened composite mineral plate: According to the ratio, the magnesium sulfate solution and the polyvinyl alcohol solution are blended and stirred evenly, and then light-burned magnesium oxide, plant powder, and modifier are blended and added. It is paved and hot-pressed at a hot-pressing temperature of 180 °C, a pressure of 12 Mpa, and a time of 30 min to obtain the base material layer; for 80 g / m 2 The multi-layer paper is impregnated with a resin, and the impregnating resin is melamine formaldehyde resin. After impregnation, the resin content of the multi-layer paper is 80%. Then it is hot-pressed with wood veneer at a temperature of 135 °C, a pressure of 6 Mpa, and a hot-pressing time of 20 min to form a reinforcing layer. The above preparation method is repeated to make a decorative layer with melamine pattern paper and a 1-mm-thick wood veneer. The upper and lower surfaces of the base material layer are evenly coated with a two-component polyurethane adhesive, and then cold-pressed and bonded with the reinforcing layer and the decorative layer under a pressure of 17 Mpa, so that the wood fiber directions of the reinforcing layer and the decorative layer are the same and are staggered with the direction of the base material layer. After curing, it is cut and trimmed to obtain a reinforced and toughened composite mineral plate.

[0031] Example 4 Reinforced and toughened composite mineral plate: It includes a base material layer, a decorative layer located on the base material layer, and a reinforcing layer under the base material layer; the reinforcing layer is formed by hot pressing melamine impregnated paper and a 3-mm-thick wood veneer, the decorative layer is formed by hot pressing melamine pattern paper and a 1-mm-thick wood veneer, and the base material layer includes the following components in parts by weight: 280 g of light-burned magnesium oxide, 220 g of magnesium sulfate solution, 100 g of polyvinyl alcohol solution, 160 g of plant powder, 10 g of modifier, and the modifier is citric acid monohydrate: sodium sulfate: phosphoric acid with a mass ratio of 9:2:6.

[0032] Preparation process of the reinforced and toughened composite mineral plate: According to the ratio, mix and stir the magnesium sulfate solution and the polyvinyl alcohol solution evenly, then add the light-burned magnesium oxide, plant powder, and modifier and mix them, lay them and perform hot pressing. The hot pressing temperature is 180 °C, the pressure is 12 Mpa, and the time is 30 min to obtain the base material layer; impregnate multiple layers of paper with resin, and the impregnated resin is melamine formaldehyde resin. The resin content of the impregnated multiple layers of paper is 80%, and then hot press with the wood veneer. The temperature is 135 °C, the pressure is 6 Mpa, and the hot pressing time is 20 min to form the reinforcing layer; repeat the above preparation method to make the decorative layer with melamine pattern paper and a 1-mm-thick wood veneer; spray 0.1-mm-thick aluminum oxide on the upper surface of the decorative layer as the aluminum oxide layer; evenly coat the upper and lower surfaces of the base material layer with two-component polyurethane adhesive, and then cold press and bond with the reinforcing layer and the decorative layer under a pressure of 17 Mpa, so that the wood fiber directions of the reinforcing layer and the decorative layer are the same and staggered with the direction of the base material layer. After curing, cut and trim to obtain the reinforced and toughened composite mineral plate. 2 Impregnate multiple layers of paper with resin, and the impregnated resin is melamine formaldehyde resin. The resin content of the impregnated multiple layers of paper is 80%, and then hot press with the wood veneer. The temperature is 135 °C, the pressure is 6 Mpa, and the hot pressing time is 20 min to form the reinforcing layer; repeat the above preparation method to make the decorative layer with melamine pattern paper and a 1-mm-thick wood veneer; spray 0.1-mm-thick aluminum oxide on the upper surface of the decorative layer as the aluminum oxide layer; evenly coat the upper and lower surfaces of the base material layer with two-component polyurethane adhesive, and then cold press and bond with the reinforcing layer and the decorative layer under a pressure of 17 Mpa, so that the wood fiber directions of the reinforcing layer and the decorative layer are the same and staggered with the direction of the base material layer. After curing, cut and trim to obtain the reinforced and toughened composite mineral plate.

[0033] Example 5 Reinforced and toughened composite mineral plate: It includes a base material layer, a decorative layer located on the base material layer, and a reinforcing layer under the base material layer; the reinforcing layer is formed by hot pressing melamine impregnated paper and a 3-mm-thick wood veneer, the decorative layer is formed by hot pressing melamine pattern paper and a 1-mm-thick wood veneer, and the base material layer includes the following components in parts by weight: 280 g of light-burned magnesium oxide, 220 g of magnesium sulfate solution, 100 g of polyvinyl alcohol solution, 160 g of plant powder, 10 g of modifier, and the modifier is citric acid monohydrate: sodium sulfate: phosphoric acid with a mass ratio of 9:2:6.

[0034] Preparation process of enhanced and toughened composite mineral plate: According to the ratio, mix and stir the magnesium sulfate solution and polyvinyl alcohol solution evenly, then add the light-burned magnesium oxide, plant powder, and modifier and mix them. Lay and hot-press them. The hot-pressing temperature is 180 °C, the pressure is 12 Mpa, and the time is 30 min to obtain the base material layer. Use a PET blended fabric layer and lay 8 layers in a horizontal-longitudinal-horizontal-longitudinal manner. Use water-based acrylic acid as the adhesive to press and bond the fabric layer at 6 Mpa to form a base. Press and bond the melamine pattern paper on one side of the horizontal direction at 6 Mpa to form a decorative layer. Repeat the above base preparation method, and press and bond the melamine impregnated paper on one side of the longitudinal direction at 6 Mpa to form a reinforcing layer. Uniformly coat the upper and lower surfaces of the base material layer with a two-component polyurethane adhesive, and then cold-press and bond it with the reinforcing layer and the decorative layer at a pressure of 17 Mpa, so that the wood fiber directions of the reinforcing layer and the decorative layer are the same and staggered with the direction of the base material layer. After curing, cut and trim to obtain the enhanced and toughened composite mineral plate.

[0035] Example 6 Enhanced and toughened composite mineral plate: It includes a base material layer, a decorative layer on the base material layer, and a reinforcing layer under the base material layer. The reinforcing layer is formed by hot-pressing melamine impregnated paper and a 3-mm-thick wood veneer. The decorative layer is formed by hot-pressing melamine pattern paper and a 1-mm-thick wood veneer. The base material layer includes the following components in parts by weight: 280 g of light-burned magnesium oxide, 220 g of magnesium sulfate solution, 100 g of polyvinyl alcohol solution, 160 g of plant powder, and 10 g of modifier. The modifier is citric acid monohydrate: sodium sulfate: phosphoric acid with a mass ratio of 9:2:6.

[0036] Preparation process of enhanced and toughened composite mineral plate: According to the ratio, mix and stir the magnesium sulfate solution and polyvinyl alcohol solution evenly, then add the light-burned magnesium oxide, plant powder, and modifier and mix them. Lay and hot-press them. The hot-pressing temperature is 180 °C, the pressure is 12 Mpa, and the time is 30 min to obtain the base material layer. Use a PET blended fabric layer and lay 6 layers in a horizontal-longitudinal-horizontal-longitudinal manner. Use water-based acrylic acid as the adhesive to press and bond the fabric layer at 6 Mpa to form a base. Press and bond the melamine pattern paper on one side of the horizontal direction at 6 Mpa to form a decorative layer. Repeat the above base preparation method, and press and bond the melamine impregnated paper on one side of the longitudinal direction at 6 Mpa to form a reinforcing layer. Uniformly coat the upper and lower surfaces of the base material layer with a two-component polyurethane adhesive, and then cold-press and bond it with the reinforcing layer and the decorative layer at a pressure of 17 Mpa, so that the wood fiber directions of the reinforcing layer and the decorative layer are the same and staggered with the direction of the base material layer. After curing, cut and trim to obtain the enhanced and toughened composite mineral plate.

[0037] Example 7 Reinforced and toughened composite mineral board: It includes a base material layer, a decorative layer located on the base material layer, and a reinforcing layer under the base material layer; the reinforcing layer is formed by hot pressing melamine impregnated paper and a 3-mm-thick wood veneer, the decorative layer is formed by hot pressing melamine pattern paper and a 1-mm-thick wood veneer, and the base material layer includes the following components in parts by weight: 280 g of light-burned magnesium oxide, 220 g of magnesium sulfate solution, 100 g of polyvinyl alcohol solution, 160 g of plant powder, and 10 g of modifier. The modifier is citric acid monohydrate: sodium sulfate: phosphoric acid with a mass ratio of 9:2:6.

[0038] Preparation process of the reinforced and toughened composite mineral board: According to the ratio, blend and stir the magnesium sulfate solution and the polyvinyl alcohol solution evenly, then add the light-burned magnesium oxide, plant powder, and modifier and blend them. Lay them and perform hot pressing. The hot pressing temperature is 180 °C, the pressure is 12 Mpa, and the time is 30 min to obtain the base material layer; use a PA blended fabric layer and lay 8 layers in a horizontal-longitudinal-horizontal-longitudinal manner. Use water-based acrylic as the adhesive to press and compound the fabric layer at 6 Mpa to form a base. Press and compound the melamine pattern paper on one side horizontally at 6 Mpa to form a decorative layer; repeat the above base preparation method, and press and compound the melamine impregnated paper on one side longitudinally at 6 Mpa to form a reinforcing layer; evenly coat the upper and lower surfaces of the base material layer with a two-component polyurethane adhesive, and then cold press and bond it with the reinforcing layer and the decorative layer at a pressure of 17 Mpa, so that the wood fiber directions of the reinforcing layer and the decorative layer are the same and are staggered with the direction of the base material layer. After curing, cut and trim the edges to obtain the reinforced and toughened composite mineral board.

[0039] Example 8 Reinforced and toughened composite mineral board: It includes a base material layer, a decorative layer located on the base material layer, and a reinforcing layer under the base material layer; the reinforcing layer is formed by hot pressing melamine impregnated paper and a 3-mm-thick wood veneer, the decorative layer is formed by hot pressing melamine pattern paper and a 1-mm-thick wood veneer, and the base material layer includes the following components in parts by weight: 280 g of light-burned magnesium oxide, 220 g of magnesium sulfate solution, 100 g of polyvinyl alcohol solution, 16 g of plant powder, and 10 g of modifier. The modifier is citric acid monohydrate: sodium sulfate: phosphoric acid with a mass ratio of 9:2:6.

[0040] Preparation process of enhanced and toughened composite mineral board: According to the ratio, mix and stir the magnesium sulfate solution and polyvinyl alcohol solution evenly, then add the light-burned magnesium oxide, plant powder, and modifier and mix them. Lay them out and perform hot pressing. The hot pressing temperature is 180°C, the pressure is 12 Mpa, and the time is 30 min to obtain the base material layer; Use a PET blended fabric layer and lay 8 layers in a horizontal-longitudinal-horizontal-longitudinal manner. Use water-based acrylic as the adhesive to press and compound the fabric layer at 6 Mpa to form a base, and press and compound the melamine pattern paper on one side horizontally at 6 Mpa to form a decorative layer; Repeat the above base preparation method, and press and compound the melamine impregnated paper on one side longitudinally at 6 Mpa to form a reinforcing layer; Uniformly coat the upper and lower surfaces of the base material layer with a two-component polyurethane adhesive, and then cold press and bond it with the reinforcing layer and the decorative layer at a pressure of 17 Mpa, so that the wood fiber directions of the reinforcing layer and the decorative layer are opposite and staggered with the direction of the base material layer. After curing, cut and trim the edges to obtain the enhanced and toughened composite mineral board.

[0041] Comparative Example 1 Enhanced and toughened composite mineral board: It includes a base material layer and a decorative layer located on the base material layer; The decorative layer is hot-pressed from melamine pattern paper and a wood veneer with a thickness of 1 mm. The base material layer includes the following components in parts by weight: 280 g of light-burned magnesium oxide, 220 g of magnesium sulfate solution, 100 g of polyvinyl alcohol solution, 160 g of plant powder, and 10 g of modifier. The modifier is citric acid monohydrate: sodium sulfate: phosphoric acid with a mass ratio of 9:2:6.

[0042] Preparation process of enhanced and toughened composite mineral board: According to the ratio, mix and stir the magnesium sulfate solution and polyvinyl alcohol solution evenly, then add the light-burned magnesium oxide, plant powder, and modifier and mix them. Lay them out and perform hot pressing. The hot pressing temperature is 180°C, the pressure is 12 Mpa, and the time is 30 min to obtain the base material layer; For 80 g / m 2 Impregnate multiple layers of paper with resin. The resin for impregnation is melamine formaldehyde resin. The resin content of the impregnated multiple layers of paper is 80%. Then hot-press it with a 1-mm wood veneer at a temperature of 135°C, a pressure of 6 Mpa, and a hot-pressing time of 20 min to form a decorative layer; Uniformly coat the upper surface of the base material layer with a two-component polyurethane adhesive, and then cold press and bond it with the decorative layer at a pressure of 17 Mpa. The wood fiber of the decorative layer is staggered with the direction of the base material layer. After curing, cut and trim the edges to obtain the enhanced and toughened composite mineral board.

[0043] Comparative Example 2 Reinforced and toughened composite mineral board: It includes a base material layer and a decorative layer located on the base material layer; the decorative layer is formed by hot pressing melamine pattern paper and a veneer with a thickness of 1 mm. The base material layer includes the following components in parts by weight: 280 g of light-burned magnesium oxide, 220 g of magnesium sulfate solution, 100 g of polyvinyl alcohol solution, 160 g of plant powder, and 10 g of modifier. The modifier is citric acid monohydrate: sodium sulfate: phosphoric acid with a mass ratio of 9:2:6.

[0044] Preparation process of the reinforced and toughened composite mineral board: According to the ratio, mix and stir the magnesium sulfate solution and the polyvinyl alcohol solution evenly, then add the light-burned magnesium oxide, plant powder, and modifier and mix them. Lay them and carry out hot pressing. The hot pressing temperature is 180 °C, the pressure is 12 Mpa, and the time is 30 min to obtain the base material layer; use a PET blended fabric layer, lay 8 layers in a horizontal-longitudinal-horizontal-longitudinal manner, and use water-based acrylic as an adhesive to press and compound the fabric layer at 6 Mpa to form a base, and press and compound the melamine pattern paper at 6 Mpa on one side of the horizontal direction to form a decorative layer; evenly coat the upper surface of the base material layer with a two-component polyurethane adhesive, and then cold press and bond it with the decorative layer under a pressure of 17 Mpa, so that the veneer fibers of the decorative layer are staggered with the direction of the base material layer. After curing, cut and trim the edges to obtain the reinforced and toughened composite mineral board.

[0045] Performance testing The performance of the reinforced and toughened composite mineral board prepared in the examples and comparative examples was tested by the following method: a: Refer to GB / T17657-2013 to measure the internal bond strength and modulus of rupture of Examples 1-8 and Comparative Examples 1-3; the test results are shown in Table 1: Table 1 Performance test results As can be seen from Table 1, for the reinforced and toughened composite mineral board prepared in the above examples and comparative examples, the internal bond strength of the composite mineral board is between 2.5 - 4.9 MPa, and the modulus of rupture reaches 53 - 79 MPa, featuring good strength. At the same time, there are fewer cracks visible under a 10x magnifying glass during winding, showing excellent flexibility.

[0046] Comparing Example 3, Example 4, and Comparative Example 1, it can be seen that for the base material layer mainly made of minerals such as magnesium oxide, by coating a two-component polyurethane adhesive on the upper and lower surfaces to bond the decorative layer and the reinforcing layer on the upper and lower surfaces, a sandwich structure is formed for the base material layer, improving the strength and toughness of the entire composite mineral board; by using melamine pattern paper and veneer, hot pressing is carried out under high temperature and high pressure to form a decorative layer; by setting an aluminum oxide layer as an abrasion-resistant layer on the decorative layer on the upper surface of the base material layer, the abrasion resistance and water resistance of the composite mineral board are improved, further enhancing the mechanical properties and environmental protection of the composite mineral board.

[0047] Comparing Example 5 with Examples 6 - 8 and Comparative Example 2, it can be seen that the reinforcing layer and the decorative layer adopt a thermoplastic blended fabric layer structure with multi - layer horizontal and vertical alternating adhesives. The unique staggered laying can make the stress distribution uniform among the layers. When subjected to complex external stresses, the horizontal and vertical fabric layers restrain each other, effectively resisting external forces such as bending, stretching, and compression, greatly enhancing the overall structural stability and reducing the possibility of deformation and damage. The thermoplastic blended fabric itself has a certain strength and toughness, and the multi - layer staggered structure further enhances this property. When subjected to external impact, each layer cooperates with each other to disperse and absorb energy synergistically, avoiding local damage caused by stress concentration, and significantly improving the overall strength and toughness. The decorative layer is longitudinally bonded with a melamine - impregnated pattern paper, which not only brings rich decorative effects to meet diverse aesthetic needs, but also can effectively resist scratching, stains, and chemical erosion, protecting the internal structure. And it makes the reinforcing layer waterproof, moisture - proof, and high in hardness. Furthermore, it enhances the peel strength and toughens the substrate layer. The process of this application first performs hot pressing, and makes the wood fiber directions of the upper and lower reinforcing layers consistent, so that there is a certain static friction between the reinforcing layer and the middle substrate layer, improving the interfacial bonding ability between the layers of the board, enhancing the internal bonding strength and peel strength, and making the direction of the substrate staggered with the horizontal and vertical directions of the reinforcing layers on the upper and lower surfaces, with the directions of the upper and lower reinforcing layers being the same. The purpose is to form a restriction on the substrate layer by the upper and lower surfaces after staggering with the substrate layer, which can effectively control material deformation, displacement, and dimensional changes, and to a certain extent improve the limitation of easy deformation during pressing in the production process of magnesium oxide boards.

[0048] The above are all preferred embodiments of this application. The protection scope of this application is not limited hereby. 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. An enhanced and toughened composite mineral plate, characterized in that: The board includes a base material layer, a decorative layer on the base material layer, and a reinforcing layer under the base material layer.

2. The enhanced and toughened composite mineral plate according to claim 1, wherein: The base material layer includes the following components in parts by weight: 28-45 parts of light-burned magnesium oxide powder, 18-22 parts of magnesium sulfate heptahydrate, 10-19 parts of polyvinyl alcohol solution, 16-18 parts of plant powder, 0.5-1 part of modifier; the modifier is citric acid monohydrate: sodium sulfate: phosphoric acid; the fineness of the plant powder is 20-120 mesh.

3. The toughened and reinforced composite mineral plate according to claim 1, wherein: The reinforcing layer is hot-pressed from melamine impregnated paper with a weight of 70 - 300 g / m 2 and veneer with a thickness of 0.3 - 3 mm.

4. The toughened and reinforced composite mineral plate according to claim 1, wherein: The decorative layer is formed by hot pressing a melamine pattern paper and a wood veneer with a thickness of 0.5-1 mm.

5. The enhanced and toughened composite mineral plate according to claim 1, wherein: The reinforcing layer includes a base layer with a structure of 6-8 layers of horizontally and vertically alternately glued thermoplastic blended fabric layers, and a melamine impregnated paper is adhered to one side of the base layer horizontally; the decorative layer includes a base layer with a structure of 6-8 layers of horizontally and vertically alternately glued thermoplastic blended fabric layers, and a melamine impregnated pattern paper is adhered to one side of the base layer longitudinally.

6. The enhanced and toughened composite mineral plate according to claim 4, wherein: The gluing is carried out by compounding with an adhesive, and the adhesive is one or several of waterborne acrylic acid, polyurethane, and polyvinyl alcohol.

7. The toughened and strengthened composite mineral plate according to claim 4, wherein: The thermoplastic blended fabric is one or two of PET and PA.

8. The preparation process of the reinforced and toughened composite mineral plate according to claims 1-6, characterized in that: According to the ratio, the raw materials of the base material layer are blended, paved, and hot-pressed into shape to obtain the base material layer. The upper and lower surfaces of the base material layer are evenly coated with a two-component polyurethane adhesive, and then cold-pressed and bonded with the decorative layer and the reinforcing layer, so that the wood fiber directions of the decorative layer and the reinforcing layer are the same and are staggered with the direction of the base material layer. After curing, it is cut and trimmed to obtain a reinforced and toughened composite mineral board.

9. The preparation process of the reinforced and toughened composite mineral plate according to claim 7, characterized in that: The hot-pressing forming conditions are 130-210 °C, the pressure is 5-20 Mpa, and the time is 10-30 min.

10. The preparation process of the enhanced and toughened composite mineral plate according to claim 7, characterized in that: The pressure of the cold-pressing bonding is 5-20 Mpa.

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