High-ductility and high-elasticity cement composite board and manufacturing process thereof

Abstract

The invention relates to the technical field of building materials, in particular to a high-ductility and high-elasticity cement composite board and a manufacturing process thereof, and the high-ductility and high-elasticity cement composite board is prepared by laying and treating bottom slurry, main materials, surface slurry and alkali-resistant glass fiber gridding cloth through the steps of vibration, extrusion, rolling, accurate thickness control and the like. The material ratio and the technological process can be optimized, the mechanical property and the physical property of the cement composite board are remarkably improved, the cement composite board has excellent tensile resistance, fracture resistance and impact resistance and good ductility and stability, and meanwhile light weight, environment friendliness and construction convenience are achieved. The composite board is suitable for the fields of building interior and exterior wall structures, various container floors, indoor and outdoor decoration, fire prevention, water prevention and the like, and meets diversified and multifunctional requirements.

Description

Technical Field

[0001] This invention belongs to the field of building materials technology, specifically relating to a high-ductility and high-elasticity cement composite board and its manufacturing process. Background Technology

[0002] Existing cement-based composite panels generally suffer from problems such as high brittleness, poor ductility, and insufficient impact resistance. Traditional production processes often employ high-temperature and high-pressure steam curing, which results in high energy consumption, long production cycles, and high costs. Furthermore, existing products fail to meet the demands of modern architecture for multifunctional materials in terms of lightweighting, mechanical properties, durability, and ease of construction.

[0003] Fiber cement board refers to a type of board made from cement as the basic material and adhesive, and mineral fibers and other fibers as reinforcing materials, through processes such as pulping, molding, and curing. Fiber cement board is widely used in fire-retardant applications in cable engineering in various power plants, chemical enterprises, and other locations with dense electrical installations. It is also an important material for fire-retardant interior decoration projects in public places such as large shopping malls, hotels, guesthouses, cultural centers, enclosed clothing markets, light industrial markets, and theaters. Fiber cement board possesses numerous superior properties such as fire resistance, water resistance, high strength, weather resistance, and environmental friendliness, resulting in a wide range of applications. With the diversification of social needs, the surface decoration effects of the boards are gradually becoming more personalized and diversified to meet the higher requirements of users.

[0004] Traditional fiber cement boards, also known as fiber-reinforced cement boards, are primarily made from fibers and cement. The reinforcement involves adding a greater proportion of various fibers to the cement; these boards contain no other raw materials besides cement and fibers. In recent years, due to changing market demands, some fiber cement boards have incorporated a certain proportion of fly ash or silica fume. These boards are typically produced using either the slurry method or the sheet forming method. The slurry method involves mixing cement and various fibers into a fluid slurry, which is then spread on a template and simply rolled to level it, thus forming the product. However, boards produced using this process have lower mechanical properties and are difficult to maintain stability; in particular, parameters such as the water-cement ratio and slump of the cement product can be significantly affected during production. The sheet forming method is generally used to produce calcium silicate boards (also known as cement pressure boards). This method requires the mixed slurry to be sheeted and drained, and after forming, the product undergoes high-temperature and high-pressure autoclaving. While this process can improve some performance, the initial investment cost is high, and when the product is steam-cured in the range of 180℃ to 220℃, temperature instability or inconsistent temperature control between batches can easily lead to temperature differences, resulting in significant variations in product performance.

[0005] In recent years, due to market reasons, many calcium silicate boards have also used different types of mineral wool as raw materials. This makes the boards prone to cracking, delamination, or blistering after being soaked in rainwater, and may even fall apart. In addition, due to their high density and weight, and the lack of a fiberglass cloth to consolidate the product, these boards are not only inconvenient to use, but also prone to breakage in practical applications, resulting in poor safety. Summary of the Invention

[0006] The purpose of this invention is to provide a high-ductility, high-elasticity cement composite board and its manufacturing process, particularly a high-ductility, high-elasticity cement composite board and its manufacturing process achieved through optimized material proportions and process flow. The cement composite board provided by this invention possesses excellent mechanical and physical properties, and exhibits significant advantages in terms of lightweight, environmental friendliness, and ease of construction.

[0007] To achieve this objective, the present invention adopts the following technical solution:

[0008] In a first aspect, the present invention provides a method for manufacturing a high-ductility, high-elasticity cement composite board, the method comprising the following steps:

[0009] The base slurry is laid on the template and leveled to a thickness of 1-2mm. Then, one or two layers of alkali-resistant fiberglass mesh are laid on the bottom layer. Next, the main material is laid and subjected to two vibration, extrusion, and roller pressing processes. Then, one or two layers of alkali-resistant fiberglass mesh are laid on the surface layer. Then, the surface slurry is laid and vibrated for the third time while being leveled. After the first cumulative thickness control is completed, three extrusion and leveling processes are performed in sequence, followed by a second round of cumulative error correction for the entire board and three rounds of water leveling. Finally, the board is cured at a temperature of 18-25℃ and a relative humidity of 65%-85% to ensure that the product meets the demolding requirements and is finally formed into the high-ductility and high-elasticity cement composite board.

[0010] The base slurry and top slurry both contain cement, quartz sand, concrete-specific gel, polypropylene fiber, latex powder, and water. The main materials include cement, coarse aggregate, fine aggregate, lightweight aggregate, polypropylene fiber, wood fiber, concrete-specific gel, and water-retaining material.

[0011] In this invention, the alkali-resistant glass fiber mesh has a specification of 180g / m² or 150g / m², and is used for the bottom layer and the top layer of the board, respectively. It accounts for 10%-15% of the total thickness of the composite board, the mesh size is 4x5mm or 5x7mm, the impregnation material is vinyl ester resin, and the impregnation amount is 15%-20% of the weight of the alkali-resistant glass fiber mesh.

[0012] This invention specifically selects alkali-resistant glass fiber mesh as a reinforcing material, which makes the final high-ductility and high-elasticity cement composite board exhibit excellent mechanical properties such as tensile strength, flexural strength, and impact resistance, while also possessing good ductility and overall stability.

[0013] The vibration frequency is 20-50Hz, the amplitude is 0.5-2mm, the extrusion pressure is 5-10MPa, and the roller speed is 0.5-2m / min. The single-pass slurry thickness error is controlled within ±0.2mm, and the standard for the second round of cumulative error correction is a final error ≤ ±0.1mm.

[0014] In this invention, the curing is divided into two stages: the first stage is carried out under natural temperature of 18-25℃ and relative humidity of 65%-85% for 10-12 hours, curing until there is no water seepage on the surface of the specimen; the second stage is carried out under the same conditions for 10-12 hours, continuing to cure until the strength reaches 85% of the design value.

[0015] This also includes applying a coating to the product surface after maintenance, using a transparent protective agent to improve the product's abrasion resistance and waterproof performance.

[0016] The base slurry comprises the following components: 20-40 parts cement, 30-45 parts quartz sand, 0.3-0.8 parts concrete-specific gel, 0.1-0.5 parts polypropylene fiber, 0.2-0.5 parts latex powder, and 25-35 parts water; the main material comprises the following components: 25-35 parts cement, 15-25 parts coarse aggregate, 10-20 parts fine aggregate, 13-28 parts lightweight aggregate, 0.2-0.6 parts polypropylene fiber, 0.3-0.8 parts wood fiber, 0.5-1.2 parts concrete-specific gel, 0.1-0.3 parts water-retaining material, and 20-40 parts water.

[0017] The base slurry comprises 30 parts cement, 40 parts quartz sand, 0.5 parts concrete-specific gel, 0.3 parts polypropylene fiber, 0.4 parts latex powder, and 32 parts water; the top slurry comprises 30 parts cement, 40 parts quartz sand, 0.5 parts concrete-specific gel, 0.3 parts polypropylene fiber, 0.4 parts latex powder, and 36 parts water; the main materials comprise 30 parts cement, 20 parts coarse aggregate, 15 parts fine aggregate, 20 parts lightweight aggregate, 0.5 parts polypropylene fiber, 0.6 parts wood fiber, 1 part concrete-specific gel, 0.2 parts water-retaining material, and 30 parts water.

[0018] The lightweight aggregate is at least one of pumice, ceramsite, or hydrophobic perlite, with a particle size range of 2-10 mm.

[0019] The polypropylene fibers have a length of 15-25 mm and a diameter of 20-40 μm; the wood fibers have a fineness of 2-3 mm.

[0020] The preparation methods of the base slurry and top slurry include mixing cement, quartz sand, concrete-specific gel, polypropylene fiber, latex powder and water for 1-2 minutes at a stirring speed of 500-1000 r / min; the preparation method of the main material includes mixing cement, coarse aggregate, fine aggregate, lightweight aggregate, polypropylene fiber, wood fiber, concrete-specific gel, water-retaining material and water for 1-2 minutes at a stirring speed of 500-1000 r / min, with alternating forward and reverse stirring during the stirring process.

[0021] As a preferred embodiment of the present invention, the manufacturing method includes the following steps:

[0022] Add the specified amounts of cement, quartz sand, concrete gel, polypropylene fiber, latex powder, and water to a mixer and mix for 1-2 minutes at a speed of 500-1000 r / min to obtain the base slurry.

[0023] The base slurry is laid on the template and leveled to a thickness of 1-2mm. Then, one or two layers of alkali-resistant glass fiber mesh with a specification of 180g / m² or 150g / m² are laid.

[0024] The formula-produced cement, coarse aggregate, fine aggregate, lightweight aggregate, polypropylene fiber, wood fiber, concrete-specific gel, water-retaining material, and water are added to a mixer and mixed for 1-2 minutes at a speed of 500-1000 r / min to obtain the main material.

[0025] The main material is laid on the bottom layer of alkali-resistant glass fiber mesh cloth, and the main material is subjected to two vibration, extrusion and simultaneous roller pressing treatments. The vibration frequency is 20-50Hz, the amplitude is 0.5-2mm, the extrusion pressure is 5-10MPa, and the roller pressing speed is 0.5-2m / min.

[0026] The surface layer consists of one or two layers of alkali-resistant fiberglass mesh with a specification of 180g / m² or 150g / m².

[0027] Add the prescribed amounts of cement, quartz sand, concrete gel, polypropylene fiber, latex powder, and water to a mixer and mix for 1-2 minutes at a speed of 500-1000 r / min to obtain the surface slurry.

[0028] The surface slurry is laid on the second layer of alkali-resistant fiberglass mesh, and the surface slurry is vibrated for the third time while being leveled.

[0029] Complete the first cumulative thickness control and correct the single grouting thickness error to within ±0.2mm;

[0030] The process involves three rounds of extrusion and leveling, a second round of cumulative error correction to bring the final error to ≤ ±0.1mm, and three rounds of continuous leveling.

[0031] Curing is carried out at a temperature of 18-25℃ and a relative humidity of 65%-85%. The first stage lasts for 10-12 hours, curing until there is no water seepage on the surface of the specimen; the second stage lasts for 10-12 hours, continuing curing until the strength reaches 85% of the design value.

[0032] After curing, the product surface is coated with a transparent protective agent to obtain the high ductility and high elasticity cement composite board.

[0033] In a second aspect, the present invention provides a high-ductility, high-elasticity cement composite board prepared according to the manufacturing method described in the first aspect.

[0034] The cement composite board provided by this invention has a high surface flatness, precise geometric dimensions, and excellent flexural strength, impact resistance, and thermal insulation performance. Its apparent density is 1.2-2.2 g / cm³, thermal conductivity ≤0.3 W / (m·K), water absorption ≤35%, and it exhibits no cracking or delamination after 100 freeze-thaw cycles and no cracking or delamination after 50 cycles of hot rain. After 50 soaking-drying cycles, its flexural strength retention rate is ≥70%.

[0035] Thirdly, the present invention provides an application of the high ductility and high elasticity cement composite board according to the second aspect in building interior and exterior wall construction panels, various container floors, prefabricated house floors, light (heavy) steel villa wall structures, mobile house walls, roofs, and various fireproof, waterproof, moisture-proof, and corrosion-resistant fields.

[0036] Compared with the prior art, the present invention has the following beneficial effects:

[0037] (1) The present invention suppresses the propagation of microcracks by forming a three-dimensional network structure of polypropylene fiber and latex powder in the base slurry, and reduces the density and improves the toughness of the lightweight aggregate and wood fiber in the main material. Combined with the layered laying and gradient molding process, the material properties are directionally controlled, so that the composite board achieves a balance between strength and lightweight.

[0038] (2) The present invention uses alkali-resistant glass fiber mesh cloth impregnated with vinyl ester resin. Its specific mesh structure (4x5mm or 5x7mm) forms a mechanical interlocking effect with the slurry. The impregnation layer simultaneously improves the compatibility between the fiber and the matrix interface. Combined with the two vibration processes to remove air bubbles inside the slurry, gradient extrusion to achieve material densification, and directional rolling to optimize fiber orientation, the three-step synergistic effect of "vibration-extrusion-rolling" significantly improves the interfacial bonding strength of the composite material. When subjected to load, the fiber bridging effect absorbs fracture energy, thereby making the product exhibit excellent tensile, flexural and impact resistance.

[0039] (3) This invention uses a dual size control mechanism of first cumulative thickness control and second whole plate error correction, combined with three-stage water-flow leveling process to ensure surface flatness and geometric accuracy; the water-retaining material in the main material and concrete-specific gel work together to improve the hydration reaction, and the 18-25℃ room temperature curing process avoids thermal stress damage caused by high temperature steam curing, ensuring the long-term structural stability and durability of the product, and expanding the application scenarios in complex environments such as humid and large temperature difference. Attached Figure Description

[0040] Figure 1 This is a flowchart of the front-end process of the high-ductility and high-elasticity cement composite board of the present invention.

[0041] Figure 2 This is a flowchart of the downstream process of the high ductility and high elasticity cement composite board of the present invention. Detailed Implementation

[0042] This invention provides a high-ductility, high-elasticity cement composite board and its manufacturing process, combined with the attached... Figure 1-2 Detailed description of specific embodiments of the present invention is provided below. (Appendix) Figure 1-2 It details the main steps and their sequence from the application of the base slurry to the final curing.

[0043] Example

[0044] When implementing this invention, a template is first prepared. As the foundational load-bearing component of the entire manufacturing process, the template's surface must be cleaned and treated with a release agent to ensure the uniformity and stability of the subsequent material laying, especially preventing the product from sticking to the template. The template can be made of high-strength ABS board or rigid PVC plastic board, and its dimensions can be adjusted according to actual production needs. Fixing devices are installed around the template to prevent displacement during vibration and compression. Next, a base slurry is prepared according to the formula ratio. The base slurry consists of cement, quartz sand, concrete-specific gel, polypropylene fiber, latex powder, and water. The base slurry includes 30 parts cement, 40 parts quartz sand, 0.5 parts concrete-specific gel, 0.3 parts polypropylene fiber, 0.4 parts latex powder, and 32 parts water. The above components are mixed and stirred in a mixer for 1-2 minutes at a speed of 500-1000 r / min until a uniform slurry is formed. After preparation, the base slurry is laid on the template and leveled to a thickness of 1-2 mm using a screed. When leveling, ensure the surface of the base slurry is smooth and free of obvious air bubbles or depressions. It should be noted that the concrete-specific gel is a modified polyacrylate gel, and the water-retaining material is hydroxypropyl methylcellulose ether (HPMC).

[0045] After the base slurry is laid, one or two layers of alkali-resistant fiberglass mesh are immediately applied as the bottom layer. The bottom layer of alkali-resistant fiberglass mesh has a specification of 180g / m² or 150g / m², with a mesh size of 4x5mm or 5x7mm. The impregnating material is vinyl ester resin, and the impregnation amount is 15%-20% of the weight of the alkali-resistant fiberglass mesh. The first layer of alkali-resistant fiberglass mesh must completely cover the surface of the base slurry and adhere tightly to it to ensure its reinforcing effect. During installation, care should be taken to avoid wrinkles or overlaps in the alkali-resistant fiberglass mesh, and its edges should be kept at a certain distance from the edges of the template to prevent stress concentration in subsequent processes. The total thickness of the bottom layer of alkali-resistant fiberglass mesh should account for 10%-15% of the total thickness; this proportion effectively improves the tensile strength and overall stability of the composite panel.

[0046] Next, the main material is prepared, which consists of cement, coarse aggregate, fine aggregate, lightweight aggregate, polypropylene fiber, wood fiber, concrete-specific gel, water-retaining material, and water. The main material includes 30 parts cement, 20 parts coarse aggregate, 15 parts fine aggregate, 20 parts lightweight aggregate, 0.5 parts polypropylene fiber, 0.6 parts wood fiber, 1 part concrete-specific gel, 0.2 parts water-retaining material, and 30 parts water. The lightweight aggregate is selected from at least one of pumice, ceramsite, or hydrophobic perlite, with a particle size range of 2-10 mm. The polypropylene fiber has a length of 15-25 mm and a diameter of 20-40 μm, and the wood fiber has a fineness of 2-3 mm. The above components are mixed and stirred in a mixer for 1-2 minutes at a speed of 500-1000 r / min, alternating between forward and reverse mixing to ensure thorough and uniform mixing of all components. After preparation, the main material is laid on the first layer of alkali-resistant glass fiber mesh. When laying, the thickness of the main material should be controlled so that it, together with the base slurry and the first layer of alkali-resistant glass fiber mesh, constitutes the main structural part of the composite board.

[0047] After the main material is laid, it needs to undergo two vibration, extrusion, and simultaneous rolling treatments. The vibration frequency is 20-50Hz, the amplitude is 0.5-2mm, the extrusion pressure is 5-10MPa, and the rolling speed is 0.5-2m / min. The vibration device is located above the main material, and the high-frequency vibration rearranges the particles inside the main material and removes excess air, thereby increasing the density. The extrusion device follows the vibration device, applying a certain pressure to further compact the main material and eliminate surface unevenness. The rolling device rolls the main material after the extrusion device, ensuring uniform rolling speed during the rolling process to avoid thickness deviations. The above vibration, extrusion, and rolling treatments need to be repeated twice to ensure that the density and uniformity of the main material meet the requirements.

[0048] After the main material is processed, one or two layers of alkali-resistant fiberglass mesh are immediately applied to the surface. The surface layer of alkali-resistant fiberglass mesh has a specification of 180g / m² or 150g / m², with a mesh size of 4x5mm or 5x7mm. The impregnating material is vinyl ester resin, and the impregnation amount is 15%-20% of the weight of the alkali-resistant fiberglass mesh. The surface layer of alkali-resistant fiberglass mesh must completely cover the surface of the main material and adhere tightly to it. Wrinkles or overlaps should be avoided during application. The total thickness of the surface layer of alkali-resistant fiberglass mesh accounts for 10%-15% of the total thickness, working together with the bottom layer of alkali-resistant fiberglass mesh to further improve the mechanical and physical properties of the composite board. The bottom layer of alkali-resistant fiberglass mesh (180g / m² or 150g / m²) and the surface layer of alkali-resistant fiberglass mesh (180g / m² or 150g / m²) must be of the same type and specification to ensure uniform stress distribution in the product.

[0049] Next, a surface slurry is prepared. The surface slurry formula includes 30 parts cement, 40 parts quartz sand, 0.5 parts concrete-specific gel, 0.3 parts polypropylene fiber, 0.4 parts latex powder, and 36 parts water. The preparation method involves mixing the above components in a mixer for 1-2 minutes at a speed of 500-1000 rpm until a homogeneous slurry is formed. After preparation, the surface slurry is laid on a second layer of alkali-resistant fiberglass mesh, and then subjected to a third vibration while simultaneously leveling. The vibration frequency and amplitude are the same as the vibration parameters of the main material. During leveling, a scraper tool is used to smooth the surface of the surface slurry to ensure its flatness meets requirements.

[0050] After the initial cumulative thickness control, three stages of extrusion and leveling, a second stage of cumulative error correction for the entire board, and three stages of continuous leveling are required. The initial cumulative thickness control involves using a laser thickness gauge to detect and adjust the single-layer slurry thickness error to within ±0.2mm. During the three stages of extrusion and leveling, extrusion devices and leveling tools are used to repeatedly treat the surface of the composite board to eliminate thickness deviations caused by material shrinkage or expansion. The standard for the second stage of cumulative error correction is a final error ≤ ±0.1mm. During this correction, precision measuring tools are used to detect and adjust the thickness of the composite board. The three stages of continuous leveling involve a continuous leveling process using assembly line equipment to ensure a smooth surface free of obvious defects.

[0051] After the above processes are completed, the composite board needs to be placed in a curing environment for curing, which is divided into two stages. The first stage is carried out under natural temperature conditions of 18-25℃ and relative humidity of 65%-85% for 10-12 hours, until there is no water seepage on the surface of the specimen. The second stage is carried out under the same conditions for another 10-12 hours, continuing curing until the strength reaches 85% of the design value. During the curing process, temperature and humidity need to be monitored regularly and adjusted according to the actual situation to ensure that the composite board achieves optimal performance. After curing, the product surface is coated with a transparent protective agent. During the coating process, it is necessary to ensure that the coating is uniform and without any missed areas to improve the product's wear resistance and waterproof performance.

[0052] The high-ductility and high-elasticity cement composite board prepared through the above process exhibits excellent mechanical and physical properties. Its apparent density is 1.2-2.2 g / cm³, thermal conductivity ≤0.3 W / (m·K), water absorption ≤35%, and it shows no cracking or delamination after 100 freeze-thaw cycles and no cracking or delamination after 50 cycles of hot rain. After 50 soaking-drying cycles, its flexural strength retention rate is ≥70%. This composite board can be widely used in interior and exterior wall decoration, floor decoration, prefabricated house walls, light steel villa walls, mobile home walls, container walls, and in various fireproof, waterproof, moisture-proof, and corrosion-resistant applications.

[0053] To enable those skilled in the art to fully understand and implement this invention, the specific implementation principle of this invention is further explained below in conjunction with a specific application scenario.

[0054] In actual production, the template is first fixed to the workbench, ensuring its surface is cleaned and leveled. Fixing devices are installed around the template to prevent displacement during subsequent vibration and pressing processes. Next, the base slurry is prepared according to the formula: 30 parts cement, 40 parts quartz sand, 0.5 parts concrete gel, 0.3 parts polypropylene fiber, 0.4 parts latex powder, and 32 parts water are mixed and stirred for 1-2 minutes at a speed of 800 rpm until a uniform slurry is formed. The base slurry is then laid on the template and leveled to a thickness of 1-2 mm using a screed, ensuring a smooth surface free of noticeable air bubbles or depressions. This step, by controlling the slurry's fluidity and the leveling operation, effectively ensures the uniform distribution of the base slurry, thus providing a stable base layer for subsequent structures.

[0055] After the base slurry is laid, two layers of alkali-resistant fiberglass mesh are immediately laid on the bottom layer: first, a 180g / m² layer with a 5x7mm mesh size is laid, followed by a 150g / m² layer with a 4x5mm mesh size. The impregnating material is vinyl ester resin, and the impregnation amount is 18% of the weight of the alkali-resistant fiberglass mesh. During installation, it is essential to ensure that the mesh completely covers the surface of the base slurry and adheres tightly to it, avoiding wrinkles or overlaps. The first layer of alkali-resistant fiberglass mesh accounts for 10%-15% of the total thickness. This proportion, through the reasonable distribution of reinforcing material, significantly improves the tensile strength and overall stability of the composite panel. Simultaneously, maintaining a certain distance between the mesh edge and the template edge prevents cracking caused by stress concentration in subsequent processes.

[0056] Next, the main material is prepared by mixing 30 parts cement, 20 parts coarse aggregate, 15 parts fine aggregate, 20 parts lightweight aggregate, 0.5 parts polypropylene fiber, 0.6 parts wood fiber, 1 part concrete-specific gel, 0.2 parts water-retaining material, and 30 parts water for 1-2 minutes at a stirring speed of 800 rpm. The stirring process involves alternating between forward and reverse rotation to ensure thorough and uniform mixing of all components. After preparation, the main material is laid on top of two layers of alkali-resistant fiberglass mesh, with its thickness controlled so that it, together with the base slurry and the two layers of alkali-resistant fiberglass mesh, constitutes the main structural part of the composite board. The lightweight aggregate in the main material is selected from pumice, ceramsite, or water-repellent perlite, with a particle size range of 2-10 mm. This choice of material not only reduces the overall density of the composite board but also improves its thermal insulation performance.

[0057] After the main material is laid, it needs to undergo two vibration, extrusion, and simultaneous rolling processes. The vibration device, positioned above the main material, uses high-frequency vibration to rearrange the particles inside and expel excess air, thereby increasing density. The vibration frequency is 20-50Hz, and the amplitude is 0.5-2mm. This parameter range effectively avoids material delamination or uneven density caused by insufficient or excessive vibration. The extrusion device follows immediately after the vibration device, applying a pressure of 5-10MPa to further compact the main material and eliminate surface unevenness. The rolling device then rolls the main material after the extrusion device at a speed of 0.5-2m / min, ensuring uniform speed during rolling to avoid thickness deviations. These vibration, extrusion, and rolling processes must be repeated twice to ensure the required density and uniformity of the main material.

[0058] After the main material is processed, two layers of alkali-resistant fiberglass mesh are laid on the surface. First, a 150g / m² layer of alkali-resistant fiberglass mesh with a 4x5mm mesh size is laid; then, a 180g / m² layer of alkali-resistant fiberglass mesh with a 5x7mm mesh size is laid. The impregnating material is vinyl ester resin, and the impregnation amount is 15%-20% of the weight of the alkali-resistant fiberglass mesh. During installation, it is essential to ensure that the mesh completely covers the surface of the main material and adheres tightly to it, avoiding wrinkles or overlaps. The total thickness of the surface layer of alkali-resistant fiberglass mesh accounts for 10%-15% of the total thickness, working together with the bottom layer to further enhance the mechanical and physical properties of the composite board. Through the layered design of the reinforcing materials using two layers of alkali-resistant fiberglass mesh on each side, the composite board exhibits excellent performance in terms of flexural strength and ductility.

[0059] The topcoat slurry is then prepared, with a formula comprising 30 parts cement, 40 parts quartz sand, 0.5 parts concrete-specific gel, 0.3 parts polypropylene fiber, 0.4 parts latex powder, and 36 parts water. The preparation method is the same as for the base slurry. The topcoat slurry is then laid on the second layer of alkali-resistant fiberglass mesh, and subjected to a third vibration while simultaneously leveling. The vibration frequency and amplitude are the same as those for the main material. During leveling, a scraper is used to smooth the surface of the topcoat slurry to ensure its flatness meets requirements. This step, through vibration and leveling, effectively eliminates unevenness on the surface of the topcoat slurry, thereby improving the appearance quality of the composite panel.

[0060] After the initial cumulative thickness control, three extrusion and leveling processes are performed sequentially, followed by a second round of cumulative error correction and three rounds of continuous leveling. The final product manufactured using this formula has a length of 3050mm, a width of 1320mm, and a thickness of 15mm. During the three extrusion and leveling processes, extrusion equipment and leveling tools are used to repeatedly treat the surface of the composite board to eliminate thickness deviations caused by material shrinkage or expansion. The standard for the second round of cumulative error correction is a final error ≤ ±0.1mm. During this correction process, precision measuring tools are used to detect and adjust the thickness of the composite board. The three rounds of continuous leveling involve a continuous leveling process on the surface of the composite board using assembly line equipment to ensure a smooth surface free of obvious defects. These steps, through precise control of thickness and surface flatness, ensure that the composite board meets high standards in terms of geometric dimensions and appearance quality.

[0061] After the above procedures are completed, the composite board needs to be placed in a curing environment for curing. Curing is divided into two stages. The first stage is carried out at a natural temperature of 25℃ and a relative humidity of 65%-85% for 12 hours, curing until no water seepage is observed on the surface of the specimen. The second stage continues under the same conditions for another 12 hours, continuing curing until the strength reaches 85% of the design value. During the curing process, temperature and humidity need to be monitored regularly and adjusted according to actual conditions to ensure the composite board's performance reaches its optimal state. After curing, the product surface is coated with a transparent protective agent. During the coating process, it is necessary to ensure that the coating is uniform and without any missed areas to improve the product's abrasion resistance and waterproof performance. This step, through reasonable curing conditions and coating treatment, can effectively improve the durability and service life of the composite board.

[0062] To further verify the superiority of the technical solution of this invention, an embodiment and a comparative example were established for comparative analysis. The embodiment was carried out entirely according to the above parameters and processes, with stable raw material sources and a controlled production process. The comparative example used a traditional slurry method to prepare ordinary fiber cement flat plates, with only PO 42.5 cement as the cementing material, single-layer quartz sand as the aggregate, and a single layer of alkali-resistant glass fiber mesh with specifications of 180g / m² or 150g / m² as the reinforcing material. No environmentally friendly gel, latex powder, water-retaining materials, or lightweight aggregates were added, and the water-cement ratio was 0.45. The plates were formed by high-temperature steam curing (180℃, 8 hours). Both samples were cut into 2440mm×1220mm×15mm specimens and subjected to multiple performance tests. The results are shown in Table 1.

[0063] Table 1. Performance test results of cement composite board and ordinary fiber cement flat board prepared by the present invention.

[0064]

[0065] As can be seen from the table above, the embodiments of the present invention are significantly superior to the comparative examples in terms of flexural strength, impact resistance, lightweight, thermal insulation performance, durability, and production efficiency. Particularly noteworthy is that although the present invention uses room temperature curing, its mechanical properties and durability are actually superior to traditional products that have undergone high-temperature and high-pressure steam curing, demonstrating the effectiveness of material system reconstruction and process optimization. Through this room temperature curing, the composite board achieves a flexural strength of over 23.2 MPa and an impact energy of over 10 J without penetrating cracks, without high-temperature and high-pressure steam curing, while the production energy consumption is less than 20 kWh / m². 2 The production cycle of a single board is less than 10 minutes, which means that the production energy consumption is reduced by 60.8% and the production cycle is shortened to 1 / 6 of the original, reflecting a fundamental improvement in the process route.

[0066] In summary, the high-ductility and high-elasticity cement composite board prepared by the above-described process of this invention possesses excellent mechanical and physical properties. Its apparent density is 1.2-1.5 g / cm³, thermal conductivity ≤0.3 W / (m·K), water absorption ≤20%, and it exhibits no cracking or delamination after 100 freeze-thaw cycles and no cracking or delamination after 50 cycles of hot rain. After 50 soaking-drying cycles, its flexural strength retention rate is ≥70%. This composite board can be widely used in interior and exterior wall decoration panels, floor decoration panels, prefabricated house walls, light steel villa walls, mobile home walls, container walls, and in various fireproof, waterproof, moisture-proof, and corrosion-resistant applications.

[0067] The above embodiments are merely one of the preferred embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-substantial modifications or alterations made to the main design concept and spirit of the present invention that solve the same technical problem as the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for manufacturing a high-ductility, high-elasticity cement composite board, characterized in that, The manufacturing method includes the following steps: The base slurry is laid on the template and leveled to a thickness of 1-2mm. Then, one or two layers of alkali-resistant fiberglass mesh are laid on the bottom layer. Next, the main material is laid and subjected to two vibration, extrusion, and roller pressing processes. Then, one or two layers of alkali-resistant fiberglass mesh are laid on the surface layer. Then, the top slurry is laid and subjected to a third vibration and leveling. After the first cumulative thickness control is completed, three extrusion and leveling processes are performed in sequence, followed by a second correction of the cumulative error of the entire board and three water-cooled leveling processes. Finally, the board is cured at a temperature of 18-25℃ and a relative humidity of 65%-85% to ensure that the product meets the demolding requirements and is finally formed into the high ductility and high elasticity cement composite board. The base slurry and top slurry both contain cement, quartz sand, concrete-specific gel, polypropylene fiber, latex powder, and water. The main materials include cement, coarse aggregate, fine aggregate, lightweight aggregate, polypropylene fiber, wood fiber, concrete-specific gel, and water-retaining material.

2. The manufacturing method according to claim 1, characterized in that, The alkali-resistant glass fiber mesh has a specification of 180g / m². 2 Or 150g / m 2 It accounts for 10%-15% of the total thickness of the composite board, with a mesh size of 4x5mm or 5x7mm, and the impregnation material is vinyl ester resin, with an impregnation amount of 15%-20% of the weight of the alkali-resistant glass fiber mesh.

3. The manufacturing method according to claim 1, characterized in that, The vibration frequency is 20-50Hz, the amplitude is 0.5-2mm, the extrusion pressure is 5-10MPa, the roller speed is 0.5-2m / min, the single slurry thickness error is controlled within ±0.2mm, and the standard for the second overall plate cumulative error correction is that the final error is ≤±0.1mm.

4. The manufacturing method according to claim 1, characterized in that, The curing process is divided into two stages: the first stage is carried out under natural temperature of 18-25℃ and relative humidity of 65%-85% for 10-12 hours, until there is no water seepage on the surface of the specimen; the second stage is carried out under the same conditions for 10-12 hours, until the strength reaches 85% of the design value.

5. The manufacturing method according to claim 1, characterized in that, This also includes coating the product surface after maintenance, using a transparent protective agent as the coating material.

6. The manufacturing method according to claim 1, characterized in that, The base slurry comprises 30 parts cement, 40 parts quartz sand, 0.5 parts concrete-specific gel, 0.3 parts polypropylene fiber, 0.4 parts latex powder, and 32 parts water; the top slurry comprises 30 parts cement, 40 parts quartz sand, 0.5 parts concrete-specific gel, 0.3 parts polypropylene fiber, 0.4 parts latex powder, and 36 parts water; the main materials comprise 30 parts cement, 20 parts coarse aggregate, 15 parts fine aggregate, 20 parts lightweight aggregate, 0.5 parts polypropylene fiber, 0.6 parts wood fiber, 1 part concrete-specific gel, 0.2 parts water-retaining material, and 30 parts water.

7. The manufacturing method according to claim 1, characterized in that, The lightweight aggregate is at least one of pumice, ceramsite, or hydrophobic perlite, with a particle size range of 2-10 mm.

8. The manufacturing method according to claim 1, characterized in that, The polypropylene fibers have a length of 15-25 mm and a diameter of 20-40 μm; the wood fibers have a fineness of 2-3 mm.

9. The manufacturing method according to claim 1, characterized in that, The preparation methods of the base slurry and top slurry include mixing cement, quartz sand, concrete-specific gel, polypropylene fiber, latex powder and water for 1-2 minutes at a stirring speed of 500-1000 r / min; the preparation method of the main material includes mixing cement, coarse aggregate, fine aggregate, lightweight aggregate, polypropylene fiber, wood fiber, concrete-specific gel, water-retaining material and water for 1-2 minutes at a stirring speed of 500-1000 r / min, with alternating forward and reverse stirring during the stirring process.

10. A high-ductility, high-elasticity cement composite board prepared by the manufacturing method according to any one of claims 1-9.

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