Sound-absorbing and flame-retardant composite building material prepared from ardealite and use method of sound-absorbing and flame-retardant composite building material

Abstract

The invention discloses a sound-absorbing and flame-retardant composite building material prepared from ardealite. The sound-absorbing and flame-retardant composite building material comprises the following components in percentage by mass: 35-55% of ardealite, 15-26% of cement or / and a mineral cementing material, 8-12% of a flame retardant, 3-8% of reinforced fibers, 5-15% of a sound-absorbing functional filler and 5-12% of an adhesive, the material is prepared by taking industrial byproduct ardealite as a main gelling component and synergistically adding a composite mineral gelling material, a multi-effect flame retardant, reinforced fibers, an environment-friendly adhesive and a sound-absorbing functional filler through an optimized ratio and a low-energy-consumption process. The prepared material has excellent sound absorption performance, A-level non-combustible performance, good mechanical property and dimensional stability, is particularly suitable for industrial buildings, machine rooms, data centers, high-humidity environments and acoustic partition wall systems, meets the requirements of modern buildings for green, high-performance and composite functional building materials, and has wide application prospects. And a new high-value application path is provided for ardealite recycling.

Description

Technical Field

[0001] The present invention belongs to the field of building acoustic materials and industrial solid waste resource utilization, and specifically relates to a multifunctional sound-absorbing and flame-retardant composite building material prepared with phosphogypsum as a main raw material and its application in building components. Background Art

[0002] The development of intelligent buildings, industrial buildings, data centers, and green, high-performance public buildings has placed higher demands on the comprehensive performance of building materials. Architectural decoration and functional components must not only possess excellent mechanical and flame-retardant properties, but also possess sound absorption and heat insulation capabilities, while also meeting modern architectural design concepts such as environmental protection, low carbon, and lightweight.

[0003] While traditional gypsum board and calcium silicate board meet fire protection requirements to a certain extent, their sound absorption performance is poor. Furthermore, the production process is energy-intensive, resource-intensive, and lacks moisture resistance, making it difficult to meet the application requirements of demanding acoustic partitions, industrial scenes, and buildings in high-humidity environments. On the other hand, phosphogypsum, a byproduct of the phosphate fertilizer industry, has a huge annual output. Due to the presence of impurities (such as fluorine and phosphorus), heavy metals, and some radioactive elements, the resource utilization rate of phosphogypsum has long been low, and its large-scale stockpiling has caused serious environmental pollution and land occupation problems. Although there have been studies attempting to use phosphogypsum in common building materials such as cement and bricks, most of these studies have been limited to low-value filler applications and have failed to fully tap its potential as a high-value-added functional building material. In particular, research in the field of sound-absorbing and flame-retardant composite materials remains a research gap or in the early stages.

[0004] Therefore, there is an urgent need to develop a phosphogypsum-based multifunctional composite building material with mature technology, stable performance, environmental protection and low carbon, and both sound absorption, heat insulation and flame retardant functions. This can not only promote the high-value bulk consumption of phosphogypsum, but also meet the multiple demands of the modern high-performance construction industry for multifunctional green building materials, and expand the application space of phosphogypsum in intelligent buildings, industrial buildings, public space acoustic partitions and other fields. Summary of the Invention

[0005] The present invention provides a sound-absorbing and flame-retardant composite building material prepared using phosphogypsum. The composition and mass percentage of the sound-absorbing and flame-retardant composite building material are 35-55% of phosphogypsum, 15-26% of cement or / and mineral cementitious material, 8-12% of flame retardant, 3-8% of reinforcing fiber, 5-15% of sound-absorbing functional filler, and 5-12% of adhesive. The material uses phosphogypsum as the main cementitious material, and is compounded with sound-absorbing functional filler, composite flame retardant, reinforcing fiber and high-performance environmentally friendly adhesive. The multifunctional sound-absorbing and flame-retardant composite building structure is prepared through a low-energy consumption process. The material further proposes a method for its application in various special building structures such as industrial buildings, data centers, transportation hubs, and public buildings.

[0006] The phosphogypsum is a by-product of the wet phosphoric acid process, which is dried to a moisture content of less than 10% and crushed to a particle size of less than 100 meshes.

[0007] The mineral cementitious material is selected from blast furnace slag powder and metakaolin.

[0008] The flame retardant is one or more of aluminum hydroxide flame retardant, magnesium hydroxide flame retardant and borate flame retardant, and the mass ratio of borate in the borate flame retardant is not less than 3%.

[0009] The reinforcing fiber is basalt fiber (5-12 mm), the sound-absorbing functional filler is hollow glass microspheres, the hollow glass microspheres have a true density of 0.32-0.40 g / cm³, a compressive strength of not less than 2000 psi, and a particle size of 85-90 μm; the adhesive is selected from epoxy modified emulsion and polyacrylate.

[0010] When the above materials are used, phosphogypsum, cement and / or mineral cementitious materials, flame retardants, reinforcing fibers, and sound-absorbing fillers are mixed, stirred and mixed, and then adhesives and water are added, with a solid-liquid ratio of g:mL of 1:0.4-0.6. After further stirring and mixing, the mixture is molded or cast, and dried and cured at 60-80°C for 12-24 hours to promote internal hydration reaction and the formation of a sound-absorbing porous structure, while reducing the free water content and improving dimensional stability, thereby obtaining a sound-absorbing and flame-retardant composite building component.

[0011] Steel or polyethylene molds are selected, and the inner wall is coated with a release agent. The mold can be designed into various specifications such as sound-absorbing and flame-retardant panels, industrial partition boards, modular components, etc. according to product requirements.

[0012] According to application requirements, the surface of sound-absorbing and flame-retardant composite building components can be treated as follows: Lamination treatment: Use PVC film, functional sound-absorbing porous coating or inorganic coating for hot pressing to improve the decorative, anti-fouling, moisture-proof and sound-absorbing properties.

[0013] Spraying treatment: Use water-based paint, fluorocarbon paint, inorganic mineral paint or acoustic coating to form a high-performance fire-proof and sound-absorbing exterior layer.

[0014] Edge trimming: The edges of the panels are polished and shaped to ensure smooth and beautiful construction joints and improve the overall sound absorption performance of the system.

[0015] The material of the present invention has a sound absorption coefficient NRC ≥ 0.6 (at a common frequency band of 1kHz), a flexural strength of not less than 8MPa, and a fire protection rating that meets GB 8624-2012 Class A. The material can be processed into standard building components such as sound-absorbing and flame-retardant wall panels, ceiling panels, partition panels, or industrial fireproof sound insulation panels. The material can be used in sound-absorbing and flame-retardant partition walls, ceiling systems, and fireproof sound insulation structures in building spaces such as data centers, computer rooms, industrial plants, transportation hubs, hospitals, schools, and buildings in high-humidity environments. It can also be used in high-performance sound-absorbing and flame-retardant non-load-bearing wall components of prefabricated buildings, combining lightweight, heat-insulating, sound-absorbing, fire-resistant, and environmentally friendly properties.

[0016] The material of the present invention not only has excellent flame retardant and mechanical properties, but also has good sound absorption and heat insulation properties, realizing multifunctional integration of sound absorption, heat insulation, fire prevention, light weight, and environmental protection, and provides a new way for the high value-added resource utilization of phosphogypsum. DETAILED DESCRIPTION

[0017] The present invention will be further described below with reference to the examples. However, the scope of the present invention is not limited to the following examples. Those skilled in the art will appreciate that various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. The instruments, reagents, and materials involved in the following examples, unless otherwise specified, are all conventional instruments, reagents, and materials already available in the prior art and can be obtained through regular commercial channels. The experimental methods, detection methods, etc. involved in the following examples, unless otherwise specified, are all conventional experimental methods and detection methods already available in the prior art; Example 1: Preparation method of standard multifunctional sound-absorbing and flame-retardant composite board 1. The composition and weight percentage of the composite building material are: phosphogypsum 40.82%, ordinary Portland cement (P.O42.5) 20.41%, blast furnace slag powder 5.11%, aluminum hydroxide flame retardant 8.16%, borate flame retardant 2.04%, basalt fiber (6mm, chopped) 4.08%, sound-absorbing functional filler (hollow glass microspheres) 12.24%, epoxy modified emulsion (50% solid content) 7.14%; 2. Premix phosphogypsum (phosphogypsum dried at 90°C to a moisture content of 8% and crushed to a particle size of ≤100 mesh), ordinary Portland cement, blast furnace slag powder, flame retardant, basalt fiber, and sound-absorbing filler in a forced mixer for 3 minutes. Slowly add epoxy modified emulsion and water (solid-liquid ratio g:mL is 1:0.47) and continue stirring for 10 minutes to form a uniform slurry with good fluidity and plasticity. The slurry should be formed within 30 minutes after stirring to avoid pre-hardening affecting performance. Pour the stirred slurry into a 300mm×300mm×12mm mold and vibrate it on a vibration table for 1 minute to eliminate bubbles and improve the homogeneity of the board. The mold should be made of polyethylene-coated steel and pre-coated with release agent. The mold is placed in a 60-70℃ drying room for 18 hours, and then naturally cooled after demoulding. This process controls the hydration degree and porosity of the board, ensures the mechanical strength, and produces a multifunctional sound-absorbing and flame-retardant composite board; The surface is sprayed with a sound-absorbing porous inorganic mineral coating to improve the overall sound absorption effect, anti-fouling and durability.

[0018] After testing, the sound absorption coefficient of this embodiment is NRC=0.68 (at the common frequency band of 1kHz), the flexural strength is 8.5 MPa, the thermal conductivity is 0.17W / (m•K), and the fire protection grade reaches GB 8624-2012 A.

[0019] Example 2: Multifunctional sound-absorbing and flame-retardant composite board for high humidity environment 1. The composition and weight percentage of the composite building material are: phosphogypsum 44.64%, ordinary Portland cement (P.O42.5) 22.32%, aluminum hydroxide flame retardant 8.93%, basalt fiber (6mm, chopped) 4.46%, sound-absorbing functional filler (hollow glass microspheres) 10.71%, and polyacrylate emulsion (50% solid content) 8.94%; 2. Premix phosphogypsum (dried at 90°C to a moisture content of 5% and crushed to a particle size of ≤100 mesh), ordinary Portland cement, flame retardant, basalt fiber, and sound-absorbing filler in a forced mixer for 3 minutes. Slowly add polyacrylate emulsion and water (solid-liquid ratio g:mL: 1:0.45) and continue stirring for 12 minutes to form a uniform slurry with good fluidity. Pour the stirred slurry into a 300mm×300mm×12mm mold, apply a release agent to the mold, and use an absorbent cloth pad on the bottom; The mold is placed in a 60°C curing box for 24 hours. Cover with a wet cloth for 4 hours before curing to keep the surface moist, promote uniform curing, form sound-absorbing pores, and prevent early cracking. After curing, it is naturally cooled to room temperature and demoulded. The edges of the board are polished and trimmed to produce a multifunctional sound-absorbing and flame-retardant composite board for high-humidity environments. After testing, the sound absorption coefficient of this embodiment is NRC=0.66 (at the common frequency band of 1kHz), the flexural strength is 8.8MPa, the thermal conductivity is 0.18W / (m•K), and the fire protection grade reaches GB 8624-2012 A.

[0020] Example 3: Film-coated multifunctional sound-absorbing and flame-retardant composite decorative board 1. The composition and composite board of this embodiment are prepared in the same manner as in Example 1; 2. Lamination treatment Covering material: porous sound-absorbing PVC film, thickness 0.25 mm Hot pressing temperature: 115℃ Pressing time: 20 seconds Pressing pressure: 0.2 MPa Cooling method: natural cooling and shaping 3. Board surface pretreatment Use 800-grit sandpaper to lightly sand the front of the board to remove dust and impurities; wipe the surface with alcohol cotton and dry it to ensure the surface is clean.

[0021] 4. Lamination Align the cut porous sound-absorbing PVC film on the surface of the board, leaving a 3-5 mm margin on the four sides; place the whole thing on the hot pressing platform, apply 0.2 MPa pressure, hot pressing temperature 115℃, and pressing time 20 seconds.

[0022] 5. Cooling and shaping After hot pressing is completed, take out the sheet immediately and place it flat on a cooling rack to cool naturally for 5 minutes to ensure that the film material is fully bonded to the substrate and there is no blistering or delamination in the film layer.

[0023] After testing, the sound absorption coefficient of this embodiment is NRC=0.7 (in the common frequency band of 1kHz), the flexural strength is 8.5MPa, the thermal conductivity is 0.17 W / (m•K), and the fire protection grade reaches GB 8624-2012 A.

Claims

1. A sound-absorbing and flame-retardant composite building material prepared using phosphogypsum, characterized in that: The composition and mass percentage are 35-55% of phosphogypsum, 15-26% of cement or / and mineral cementitious material, 8-12% of flame retardant, 3-8% of reinforcing fiber, 5-15% of sound-absorbing functional filler, and 5-12% of adhesive.

2. The sound-absorbing and flame-retardant composite building material prepared using phosphogypsum according to claim 1, characterized in that: The mineral cementitious material is selected from blast furnace slag powder and metakaolin.

3. The sound-absorbing and flame-retardant composite building material prepared using phosphogypsum according to claim 1, characterized in that: The flame retardant is one or more of aluminum hydroxide flame retardant, magnesium hydroxide flame retardant and borate flame retardant.

4. The sound-absorbing and flame-retardant composite building material prepared using phosphogypsum according to claim 1, characterized in that: The reinforcing fiber is basalt fiber, and the sound-absorbing filler is hollow glass microspheres. The true density of the hollow glass microspheres is 0.32-0.40g / cm³, the compressive strength is not less than 2000 psi, and the particle size is 85-90μm.

5. The sound-absorbing and flame-retardant composite building material prepared using phosphogypsum according to claim 1, characterized in that: The adhesive is selected from epoxy modified emulsion and polyacrylate.

6. The sound-absorbing and flame-retardant composite building material prepared using phosphogypsum according to claim 3, characterized in that: The mass ratio of borate in the borate flame retardant is not less than 3%.

7. The method for using the sound-absorbing and flame-retardant composite building material prepared using phosphogypsum according to claim 1, characterized in that: The phosphogypsum, cement or mineral cementitious material, flame retardant, reinforcing fiber and sound-absorbing functional filler are mixed, stirred and evenly mixed, and then adhesive and water are added, with a solid-liquid ratio (g:mL) of 1:0.4-0.

6. The mixture is further stirred and evenly mixed, and then molded or cast, and dried and cured at 60-80°C for 12-24h to obtain a sound-absorbing and flame-retardant composite building component.

8. The method of use according to claim 7, characterized in that: The surface of sound-absorbing and flame-retardant composite building components is coated with inorganic mineral coatings, sound-absorbing porous coatings or PVC decorative films to improve stain resistance, sound absorption performance and appearance performance.

9. The method of use according to claim 7, characterized in that: The sound-absorbing and flame-retardant composite building component is a sound-absorbing and flame-retardant wall panel, a ceiling panel or a partition panel.