Integrated forming preparation process of heat-preservation, heat-insulation and fireproof inorganic honeycomb plate

Abstract

The invention relates to the technical field of building heat preservation and fireproof materials, in particular to a heat preservation, heat insulation and fireproof inorganic honeycomb plate integrated forming preparation process which comprises the following steps: S1, preparing inorganic composite slurry; s2, honeycomb core pretreatment; s3, integrally forming; and S4, maintenance and post-treatment. According to the method, the problems of interlayer stripping and core material deformation caused by weak interface bonding are solved, the forming size precision and the uniformity of an internal structure are guaranteed, and a continuous, efficient and stable process basis is achieved.

Description

Technical Field

[0001] This invention relates to the field of building insulation and fireproofing materials technology, specifically to an integrated molding process for thermal insulation and fireproof inorganic honeycomb panels. Background Technology

[0002] In the field of building insulation and fireproofing materials, inorganic honeycomb panels have attracted attention due to their lightweight, high strength, and good fire resistance potential. However, traditional manufacturing processes typically face several common challenges: First, under complex stress and temperature and humidity changes, interlayer delamination is prone to occur within the panels, affecting structural safety and durability; second, the honeycomb core material is easily deformed during processing or load-bearing, making it difficult to control the dimensional accuracy and flatness of the product; third, ensuring that the fire resistance performance of the core material and the surface material is consistent, and avoiding the core material becoming a weak link in the overall fire protection chain due to its flammability, is key to improving the product's safety level.

[0003] Currently, most common inorganic honeycomb panels employ a discrete "form-then-composite" process. Patent CN104631693A discloses an interior partition wall panel and its preparation method, which mixes inorganic fibers with an adhesive and then forms a honeycomb spur panel using a corrugated film-forming machine. This panel can be arbitrarily cut and assembled according to the building's module, reducing the amount of masonry work required for traditional secondary structures. It also saves on wall tie bars and seismic embedded parts under beams. However, this process has a long production flow, and a secondary composite with the panel is still required. The interface bonding strength often depends on additional adhesives, failing to achieve integrated molding of the substrate and structure. The patent with publication number CN101153686A discloses a fireproof and heat-insulating honeycomb composite material product with high bending strength and its manufacturing method. It adopts a distribution process of filling the molded honeycomb cells with lightweight inorganic materials and then applying gel material to the end face. This process retains the high strength and softness of the honeycomb structure, while also providing superior fireproof, flame-retardant, heat-insulating, and sound-insulating performance. The overall product has high bending load strength and improves its high impact resistance. However, the process is complex and there are bonding interfaces, which limits production efficiency and integration.

[0004] To address the prominent issue of interlayer delamination, existing technologies primarily focus on strengthening the adhesive bonding process. Patent CN103264532A discloses a composite board with high peel strength and its manufacturing process. This method improves peel strength by adding a non-woven fabric layer between the plastic or metal honeycomb core and the panel to lock in the adhesive. This patent's solution demonstrates that interlayer delamination is a common industry problem, but it relies on adding additional organic media and complex bonding processes, potentially introducing flammable components and increasing process complexity.

[0005] To enhance the functionality of honeycomb core materials, existing technologies primarily employ surface treatment or external coating methods. Patent CN100999147A discloses a production process for fire-retardant, high-strength, heat-insulating corrugated paper honeycomb composite materials, using a method of impregnating corrugated paperboard with a water-based flame retardant. Patent CN216860800U discloses an environmentally friendly, waterproof, and flame-retardant multilayer honeycomb rigid paperboard, achieving protection through the setting of multiple external functional layers, including flame-retardant and waterproof layers. While these methods have some effectiveness, the organic nature of the core material or the complex interfaces of the functional layers may still affect the durability and integrity of fire resistance, and introduce the risk of delamination over long-term use.

[0006] In summary, existing technologies and published patents often exhibit limitations in addressing issues such as structural reliability, production efficiency, and fire resistance consistency of inorganic honeycomb panels, including discrete processes, reliance on interfacial bonding, or incomplete functional modification. Therefore, there is an urgent need for an innovative solution that fundamentally integrates material systems and molding processes to achieve continuous production with integrated high efficiency, high strength, and high fire resistance. Summary of the Invention

[0007] The present invention aims to overcome the shortcomings of the prior art and provide an integrated molding process for thermal insulation and fireproof inorganic honeycomb panels and the products obtained therefrom, so as to achieve integrated and efficient production of structure, thermal insulation and fireproof performance.

[0008] To achieve the above objectives, the present invention adopts the following technical solution: A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels includes the following steps: S1. Preparation of inorganic composite slurry: Inorganic cementitious materials, lightweight thermal insulation fillers, flame-retardant fibers, water and optional additives are mixed and stirred evenly to obtain inorganic composite slurry; S2. Honeycomb core pretreatment: The paper honeycomb is immersed in a flame retardant solution and then dried to obtain a flame retardant honeycomb core; S3. Integrated molding: The flame-retardant honeycomb core obtained in step S2 is unfolded and positioned in the mold. Then, the inorganic composite slurry obtained in step S1 is poured into the cells of the flame-retardant honeycomb core. Panel material is laid on the upper and lower surfaces of the flame-retardant honeycomb core. Then, it is sent into a molding press for integrated molding. S4. Curing and post-processing: Demolding the molded blank, followed by standard curing, drying and dimensional processing, to obtain the heat-insulating, fireproof inorganic honeycomb board.

[0009] Preferably, in step S1, the inorganic composite slurry comprises, by weight, 30-50 parts of inorganic cementitious material, 20-40 parts of lightweight thermal insulation filler, 5-15 parts of flame-retardant fiber, 15-30 parts of water, and 0.5-3 parts of admixture. The inorganic cementitious material is at least one of sulfoaluminate rapid-hardening cement, ferroaluminate cement, high-alumina cement, desulfurized gypsum, and high-strength gypsum. The lightweight thermal insulation filler is at least one of expanded perlite, vitrified microspheres, closed-cell expanded perlite, cenospheres, and ceramic sand. The flame-retardant fiber is at least one of ceramic fiber, basalt fiber, glass fiber, mineral wool fiber, and aramid pulp. The admixture is at least one of water-reducing agent, retarder, accelerator, water-retaining agent, thickener, and defoamer.

[0010] This scheme defines the functional system and quantitative proportions of the inorganic composite slurry. Inorganic cementitious materials form the continuous skeleton of the slurry after curing, providing the main structural strength and stability. Their rapid hardening characteristics are fundamental to matching the continuous production rhythm; insufficient dosage leads to weak matrix strength, while excessive dosage increases self-weight and induces shrinkage stress. Lightweight insulating fillers are uniformly dispersed in the skeleton. Their porous or hollow structure effectively blocks heat flow and reduces overall density, making them the core functional components for achieving lightweighting and insulation goals. Too low a proportion results in poor insulation and lightweighting effects, while too high a proportion severely weakens matrix strength and affects slurry encapsulation. Flame-retardant fibers form a three-dimensional network in the matrix, not only providing toughening and crack resistance but, more importantly, maintaining structural shape at high temperatures, providing dimensional stability and anti-collapse capabilities during fire resistance. The fiber content must be sufficient to form an effective network, but excessive content severely impairs slurry fluidity, making it difficult to fill the honeycomb cells. Water is the medium for cementitious hydration and imparts initial fluidity; its dosage must achieve a precise balance between meeting hydration reaction and workability requirements. Admixtures are used to fine-tune the rheological properties and setting time of the slurry, ensuring that it can successfully fill complex honeycomb structures and work synergistically with subsequent molding and curing processes. This material system design fundamentally replaces a single inorganic substrate, achieving the integration of structural, thermal insulation, and fire-resistant properties simultaneously through the synergistic effect of its components, provided the process is feasible.

[0011] Preferably, in step S2, the flame retardant solution is at least one of ammonium dihydrogen phosphate solution, ammonium polyphosphate solution, zinc borate solution, and borax solution, with a mass concentration of 5%-25%; the drying temperature is 60℃-120℃, and the honeycomb core is dried until the moisture content is less than 5%.

[0012] This scheme clarifies the specific processing methods for imparting intrinsic flame-retardant functionality to the honeycomb core. Impregnation with a specific inorganic flame-retardant solution ensures the flame-retardant components penetrate deep into the paper honeycomb fibers, rather than remaining merely on the surface. This process transforms the originally combustible organic core material into an inorganic modified body with fire-retardant properties, fundamentally eliminating the fire hazard inherent in traditional paper honeycomb and ensuring consistency in fire resistance between the core material, the inorganic surface layer, and the pulp matrix. Solution concentration is crucial for ensuring the effective loading of the flame-retardant; too low a concentration results in insufficient flame-retardant efficacy, while too high a concentration may cause crystallization or affect the mechanical properties of the core material. Subsequent drying must be thorough and temperature-controlled to completely remove free moisture from the honeycomb structure. Excessive residual moisture will generate steam during subsequent high-temperature molding or use, leading to increased internal pressure, potentially causing delamination, blistering, or weakening of interfacial bonding strength. Therefore, maintaining a low moisture content is essential for ensuring overall structural stability and long-term durability.

[0013] Preferably, in step S3, the panel material is asbestos-free fiber cement board, calcium silicate board, magnesium oxide board, magnesium oxide board, aluminum foil, or metal sheet.

[0014] This approach defines the types of panel materials suitable for the integrated molding process. All selected panels are inherently non-combustible or flame-retardant, and their selection considers chemical compatibility with the inorganic slurry matrix, compatibility of thermal expansion coefficients, and interfacial bonding potential. During molding, these panels, under pressure and temperature, form a tight mechanical and physicochemical bond with the flowing slurry, rather than relying on additional organic adhesives. This bonding method avoids the risk of interlayer delamination caused by adhesive aging, creep, or poor temperature resistance in traditional composite processes, and is a key element in achieving structural integration. The rigidity of the panels also provides the necessary surface impact resistance and flatness for the entire board.

[0015] Preferably, in step S3, the process parameters for the integrated molding are: molding pressure 0.5MPa-1.5MPa, molding temperature 50℃-100℃, and holding time 10min-40min.

[0016] This scheme establishes the core process window for achieving "compression molding." The role of compression molding is to induce the flow of the inorganic slurry in a plastic state under specific temperature and pressure, thereby completely filling every cell of the honeycomb core and expelling internal air, while simultaneously achieving maximum tight contact with the honeycomb core ribs and upper and lower panels. Pressure is the primary driving force for achieving this; insufficient pressure leads to incomplete filling, internal voids, or weak interfacial bonding; excessive pressure may crush the regular structure of the honeycomb core, compromising its lightweight and high-strength advantages. Temperature has a dual function: firstly, it accelerates the early hydration reaction of the inorganic cementitious material, increasing initial strength to facilitate demolding; secondly, it appropriately reduces the viscosity of the slurry, aiding its flow and compaction under pressure. Holding time ensures the sufficiency of the effects of pressure and temperature, allowing the slurry sufficient time to redistribute, expel air, and initially bond with the contact surfaces. The synergistic optimization of these three parameters is a direct process guarantee for solving honeycomb core deformation, poor dimensional accuracy, and achieving strong interlayer bonding.

[0017] More preferably, in the integrated molding process, a segmented pressurization system is adopted: first, pre-pressurize at a pressure of 0.2MPa-0.5MPa for 1min-3min, and then increase to the molding pressure and maintain the pressure holding time.

[0018] This further optimization involves refined control of the core molding process. A segmented pressurization regime is a key process optimization. The initial low-pressure pre-compression stage allows the highly fluid slurry to flow smoothly into the honeycomb cells under lower driving force, while simultaneously guiding the gradual expulsion of internal air and achieving initial alignment and stability between the honeycomb core and the panel. Directly applying high pressure can easily lead to slurry splashing, honeycomb core displacement, or rapid blockage of local pores, trapping air and creating internal defects. The pre-compression stage provides a gentle transition period for slurry flow and air expulsion, followed by increasing to the set pressure for main compaction. This results in a more uniform and dense preform structure with good interfacial bonding and fewer internal defects, significantly improving product yield and performance consistency.

[0019] Preferably, in step S4, the standard curing conditions are: temperature 20±2℃, relative humidity above 90%, and curing time of 24h-72h; the drying treatment temperature is 40℃-80℃, and the drying is carried out until the moisture content of the board is below 10%.

[0020] This invention uses paper honeycomb treated with a flame-retardant solution as the core material. The core material's pores and upper and lower surfaces are integrally molded with a matrix and panel material formed from inorganic cementitious materials, lightweight insulating fillers, and flame-retardant fibers. This invention is not a simple stacking or bonding of multiple materials; its key feature is that the functional components are integrated into a continuous whole at both the microscopic and macroscopic levels through a molding process. There are no obvious, easily peelable physical interfaces between the flame-retardant honeycomb core, the composite inorganic matrix, and the fireproof panel; instead, a synergistic structure is formed where they are interconnected, mechanically interlocked, and chemically bonded. It is this unique "integrated" structure that endows the board with superior performance compared to traditional composite boards: high specific strength, excellent resistance to interlaminar peeling, consistent fire resistance, and reliable overall dimensional stability. This scheme specifies the necessary conditions for the material properties to stabilize after molding. Standard curing provides an ideal environment for the full hydration of the inorganic cementitious materials, which is a crucial stage for the slurry matrix to achieve its expected final strength. Suitable temperature and humidity ensure the continuous and thorough hydration reaction, and the curing time is matched to the characteristics of the selected cementitious system. Subsequent drying aims to controllably remove excess moisture from the board. The drying temperature must be gradual; excessively rapid heating or high temperatures will cause rapid moisture evaporation, generating excessive internal stress and leading to cracking or deformation. Maintaining a low final moisture content ensures dimensional stability of the board in its application environment, preventing warping or strength reduction due to moisture changes, and also helps maintain its long-term thermal insulation performance.

[0021] The present invention uses paper honeycomb treated with flame retardant solution as core material. The core material is integrally formed with the matrix and panel material, which are composed of inorganic cementitious material, lightweight thermal insulation filler and flame retardant fiber, through molding.

[0022] This invention is not a simple stacking or bonding of multiple materials; its key feature is that the functional components are integrated into a continuous whole at both the micro and macro levels through a molding process. There are no obvious, easily peelable physical interfaces between the flame-retardant honeycomb core, the composite inorganic matrix, and the fireproof panel; instead, a synergistic structure is formed where they are interconnected, mechanically interlocked, and chemically bonded. It is this unique "integrated" structure that endows the board with superior performance compared to traditional composite boards: high specific strength, excellent resistance to interlaminar peeling, consistent fire resistance, and reliable overall dimensional stability. This product claim is a material solidification and protection of the technical effects achieved by the method claim.

[0023] The technical advantages of this invention are reflected in the following aspects: From a compositional perspective, the technical advantage of this solution lies in using rapid-hardening inorganic cementitious materials as the strength framework, lightweight porous fillers as the thermal insulation component, and high-temperature resistant fibers as a toughening and high-temperature stabilizing network. This composite substrate design replaces traditional single-material designs, achieving a balance between structural strength, thermal insulation, and high-temperature resistance while ensuring lightweight construction. The intrinsic flame-retardant treatment of the honeycomb core material transforms it from a combustible organic material into a fire-retardant material, fundamentally solving the industry problem of inconsistent fire resistance between traditional paper honeycomb core materials and inorganic surface layers, ensuring the uniformity and reliability of the overall fire resistance of the board.

[0024] From a process perspective, this solution involves pouring an inorganic slurry with specific rheological properties into a pre-placed flame-retardant honeycomb core and simultaneously laying the panels. Molding is then performed under optimized temperature and pressure parameters, allowing the slurry to flow and fill the honeycomb cells while simultaneously forming a tight mechanical and chemical bond with the core material and panels. This process abandons the traditional step-by-step preparation method that relies on secondary bonding, overcoming problems such as interlayer delamination and core material deformation caused by weak interfacial bonding. Precise control, such as segmented pressurization, further ensures the dimensional accuracy and uniformity of the internal structure, achieving a continuous, efficient, and stable process foundation. Attached Figure Description

[0025] Figure 1 The finished product of the thermal insulation and fireproof inorganic honeycomb panel prepared in Example 1. Detailed Implementation

[0026] The following specific embodiments illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. General Implementation Examples

[0027] A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels, comprising the following steps: S1: Preparation of inorganic composite slurry Materials prepared by weight: 30-50 parts inorganic cementitious material, specifically, one or a mixture of several of the following: sulfoaluminate rapid-hardening cement, ferroaluminate cement, high-alumina cement, desulfurized gypsum, or high-strength gypsum; 20-40 parts lightweight thermal insulation filler, specifically, one or a mixture of several of the following: expanded perlite, vitrified microspheres, closed-cell expanded perlite, cenospheres, or ceramic sand; 5-15 parts flame-retardant fiber, specifically, one or a mixture of several of the following: ceramic fiber, basalt fiber, glass fiber, mineral wool fiber, or aramid pulp; 15-30 parts water; 0.5-3 parts admixture, specifically, one or a mixture of several of the following: water-reducing agent, retarder, accelerator, water-retaining agent, thickener, or defoamer, used to adjust the rheological and setting properties of the slurry.

[0028] First, pour the measured water into a planetary mixer and run it at a low speed of 60-100 rpm. Add the weighed additives and stir for 2-3 minutes to ensure they are fully dissolved and dispersed. Next, add the weighed inorganic cementitious material and increase the stirring speed to a medium speed of 200-300 rpm, stirring for 3-5 minutes to form a homogeneous slurry base. Finally, while maintaining stirring, gradually add the weighed lightweight thermal insulation filler and flame-retardant fibers. After all materials have been added, increase the stirring speed to a high speed of 400-500 rpm and continue stirring for 5-8 minutes until a homogeneous paste-like composite slurry with no dry powder particles and appropriate viscosity and flowability is formed. The slurry should be used in subsequent processes within 30 minutes of preparation to prevent thickening that could affect casting performance.

[0029] S2: Cellular Core Pretreatment Select paper honeycomb cores of specified specifications. Dissolve solid flame retardant in deionized water to prepare a flame retardant solution with a mass concentration ranging from 5% to 25%. The specific type of flame retardant is one or more selected from ammonium dihydrogen phosphate, ammonium polyphosphate, zinc borate, or borax. Completely immerse the paper honeycomb cores in the prepared flame retardant solution for 10-30 minutes, gently turning them during this time to ensure complete immersion. Remove the immersed honeycomb cores and place them on a draining mesh rack to stand for 5-10 minutes to remove excess solution from the surface. Then transfer them to a circulating hot air drying oven and dry them at a temperature range of 60℃-120℃ until the moisture content of the honeycomb cores is below 5%, which is determined by gravimetric method. Place the dried flame-retardant honeycomb cores in a dry environment to cool for later use.

[0030] S3: One-piece molding Clean the upper and lower molds and preheat them to a temperature range of 50℃-70℃. Take a flame-retardant honeycomb core that has been treated with S2 and whose size matches the mold, unfold it in the mold cavity, and position it precisely. Using a casting device, evenly pour the inorganic composite slurry prepared in S1 into all the cells of the honeycomb core. During casting, mechanical vibration or slight manual vibration of the mold can be used to promote slurry flow and ensure dense filling. After casting, quickly lay a layer of panel material on the upper and lower surfaces of the honeycomb core. The specific type of panel material is one of asbestos-free fiber cement board, calcium silicate board, magnesium oxide board, aluminum foil, or thin metal sheet. Close the mold and send it into a flat vulcanizing machine or a special press with heating function.

[0031] A segmented pressing process is used for molding: First, a lower pressure of 0.2-0.5 MPa is applied for pre-pressing for 1-3 minutes. Then, the pressure is steadily increased to the final molding pressure of 0.5-1.5 MPa, while maintaining the hot plate temperature within the range of 50℃-100℃. Under this set pressure and temperature, the plate is held for curing for 10-40 minutes. After the pressure holding period, the pressure is released and the plate is demolded to obtain a complete wet blank.

[0032] S4: Maintenance and Post-treatment After demolding, the wet sheet material is transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 90% for curing. The wet sheet material is placed horizontally on the curing rack, with a spacing of not less than 50 mm between the sheets. The standard curing time is 24-72 hours.

[0033] After curing, the boards are dried. The drying temperature is controlled within the range of 40℃-80℃, and the boards are dried until the moisture content is below 10%. After drying, the boards are allowed to cool to room temperature, and then cut to the required dimensions using cutting equipment. The cut edges are then ground or trimmed as necessary to obtain the finished thermal insulation, fireproof inorganic honeycomb board. Example 1

[0034] A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels, comprising the following steps: S1: Preparation of inorganic composite slurry Prepare materials by weight: 40 parts sulfoaluminate rapid-hardening cement, 30 parts closed-cell expanded perlite, 10 parts ceramic fiber, 22.5 parts water, 1.5 parts polycarboxylate superplasticizer, 0.2 parts hydroxypropyl methylcellulose ether, and 0.1 parts silicone defoamer.

[0035] First, pour the measured water into a planetary mixer and run it at a low speed of 80 rpm. Add the weighed water-reducing agent, cellulose ether, and defoamer, and mix for 2.5 minutes to ensure they are fully dissolved and dispersed. Then, add the weighed sulfoaluminate rapid-hardening cement and increase the mixing speed to 250 rpm, mixing for 4 minutes to form a homogeneous slurry base. Finally, while maintaining mixing, gradually add the weighed closed-cell expanded perlite and ceramic fibers. After all materials have been added, increase the mixing speed to 450 rpm and continue mixing for 6.5 minutes until a homogeneous paste-like composite slurry with no dry powder particles and appropriate viscosity and flowability is formed. The slurry should be used in subsequent processes within 30 minutes of preparation.

[0036] S2: Cellular Core Pretreatment A regular hexagonal paper honeycomb core with a side length of 8 mm was selected. Ammonium dihydrogen phosphate solid was dissolved in deionized water to prepare a 15% (w / w) flame retardant solution. The paper honeycomb core was completely immersed in the prepared flame retardant solution for 20 minutes, during which it could be gently turned to ensure complete immersion. After immersion, the honeycomb core was removed and placed on a draining rack to stand for 7 minutes to remove excess solution from the surface. It was then transferred to a circulating hot air drying oven and dried at 90°C for 2.5 hours until the moisture content of the honeycomb core was below 5%. The dried flame-retardant honeycomb core was then cooled in a dry environment for later use.

[0037] S3: One-piece molding Clean and preheat the upper and lower molds to 60°C. Take a flame-retardant honeycomb core that has been treated with S2 and whose size matches the mold, unfold it in the mold cavity, and position it precisely. Using a casting device, evenly pour the inorganic composite slurry prepared with S1 into all the cells of the honeycomb core. During pouring, supplement with mechanical vibration at a frequency of 50 Hz for 30 seconds to promote slurry flow and ensure dense filling. After pouring, quickly lay a 5 mm thick layer of asbestos-free fiber cement board on both the upper and lower surfaces of the honeycomb core. Close the mold and send it into a flat vulcanizing machine.

[0038] A segmented pressurization process was used for molding: first, a pressure of 0.35 MPa was applied for pre-pressing for 2 minutes. Then, the pressure was steadily increased to the final molding pressure of 1.0 MPa within 1 minute, while maintaining the hot plate temperature at 75°C. Under this set pressure and temperature, the material was held for curing for 25 minutes. After the pressure holding period, the pressure was released and the material was demolded to obtain a wet blank with a complete structure.

[0039] S4: Maintenance and Post-treatment After demolding, the wet sheet material is transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 95% for curing. The wet sheet material is placed horizontally on the curing rack, with a spacing of not less than 50 mm between the sheets. The standard curing time is 48 hours.

[0040] After curing, the boards are transferred to a drying oven for drying. The drying process involves increasing the temperature from 40℃ to 65℃ at a rate of 5℃ / h, and maintaining this temperature at 65℃ for 24 hours until the moisture content of the boards is below 10%. After drying, the boards are allowed to cool to room temperature, and then cut to the required dimensions using a CNC cutting machine. The cut edges are then polished to obtain the finished thermal insulation, fireproof, inorganic honeycomb board. Figure 1 As shown. Example 2

[0041] A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels, comprising the following steps: S1: Preparation of inorganic composite slurry Prepare materials by weight: 35 parts desulfurized gypsum, 25 parts vitrified microspheres, 8 parts basalt fiber, 20 parts water, 1.2 parts calcium lignosulfonate, and 0.3 parts citric acid.

[0042] First, pour the measured water into a planetary mixer and run it at a low speed of 70 rpm. Add the weighed calcium lignosulfonate and citric acid, and stir for 2 minutes to ensure they are fully dissolved and dispersed. Then, add the weighed desulfurized gypsum and increase the stirring speed to 220 rpm, stirring for 3.5 minutes to form a homogeneous slurry base. Finally, while maintaining stirring, gradually add the weighed vitrified microspheres and basalt fibers. After all materials have been added, increase the stirring speed to 420 rpm and continue stirring for 6 minutes until a homogeneous, dry powder-free, paste-like composite slurry with appropriate viscosity and flowability is formed. The slurry should be used in subsequent processes within 30 minutes of preparation.

[0043] S2: Cellular Core Pretreatment A regular hexagonal paper honeycomb core with a side length of 6 mm was selected. Ammonium polyphosphate solid was dissolved in deionized water to prepare an 8% (w / w) flame retardant solution. The paper honeycomb core was completely immersed in the prepared flame retardant solution for 30 minutes, during which it could be gently turned to ensure complete immersion. The immersed honeycomb core was then removed and placed on a draining rack to stand for 10 minutes to remove excess solution from the surface. It was then transferred to a circulating hot air drying oven and dried at 60°C for 4 hours until the moisture content of the honeycomb core was below 5%. The dried flame-retardant honeycomb core was then cooled in a dry environment for later use.

[0044] S3: One-piece molding Clean the upper and lower molds and preheat them to 50°C. Take a flame-retardant honeycomb core that has been treated with S2 and whose size matches the mold, unfold it in the mold cavity, and position it precisely. Using a casting device, evenly pour the inorganic composite slurry prepared with S1 into all the cells of the honeycomb core, supplementing the pouring process with slight manual vibration of the mold. After pouring, quickly lay a 0.5 mm thick layer of aluminum foil on both the upper and lower surfaces of the honeycomb core. Close the mold and send it into a flat vulcanizing machine.

[0045] A segmented pressurization process was used for molding: first, a pressure of 0.2 MPa was applied for pre-pressing for 3 minutes. Then, the pressure was steadily increased to the final molding pressure of 0.5 MPa within 1 minute, while maintaining the hot plate temperature at 50°C. Under this set pressure and temperature, the material was held for curing for 40 minutes. After the pressure holding period, the pressure was released and the material was demolded to obtain a wet blank with a complete structure.

[0046] S4: Maintenance and Post-treatment After demolding, the wet sheet material is transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 90% for curing. The wet sheet material is placed horizontally on the curing rack, with a spacing of not less than 50 mm between the sheets. The standard curing time is 72 hours.

[0047] After curing, the boards are transferred to a drying oven for drying. The drying process is carried out at a constant temperature of 40℃ for 30 hours until the moisture content of the boards is below 10%. After drying, the boards are allowed to cool to room temperature and then cut to the required dimensions using a cutting machine. The cut edges are then trimmed to obtain the finished thermal insulation, fireproof inorganic honeycomb board. Example 3

[0048] A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels, comprising the following steps: S1: Preparation of inorganic composite slurry Prepare the following materials by weight: 50 parts high-alumina cement, 20 parts ceramic sand, 15 parts aramid pulp, 30 parts water, 2.5 parts melamine-based water-reducing agent, and 0.5 parts polyvinyl alcohol.

[0049] First, pour the measured water into a planetary mixer and run it at a low speed of 100 rpm. Add the weighed water-reducing agent and polyvinyl alcohol, and mix for 3 minutes to ensure they are fully dissolved and dispersed. Then, add the weighed high-alumina cement and increase the mixing speed to 300 rpm, mixing for 5 minutes to form a homogeneous slurry base. Finally, while maintaining mixing, gradually add the weighed ceramic sand and aramid pulp. After all materials have been added, increase the mixing speed to 500 rpm and continue mixing for 8 minutes until a homogeneous paste-like composite slurry with no dry powder particles and appropriate viscosity and flowability is formed. The slurry should be used in subsequent processes within 30 minutes of preparation.

[0050] S2: Cellular Core Pretreatment A regular hexagonal paper honeycomb with a side length of 10 mm was selected. Zinc borate solid was dissolved in deionized water to prepare a 25% (w / w) flame retardant solution. The paper honeycomb was completely immersed in the prepared flame retardant solution for 10 minutes, during which it could be gently turned to ensure complete immersion. The immersed honeycomb core was then removed and placed on a draining rack for 5 minutes to remove excess solution from the surface. It was then transferred to a circulating hot air drying oven and dried at 120°C for 1.5 hours until the moisture content of the honeycomb core was below 5%. The dried flame-retardant honeycomb core was then cooled in a dry environment for later use.

[0051] S3: One-piece molding Clean the upper and lower molds and preheat them to 70°C. Take a flame-retardant honeycomb core that has been treated with S2 and whose size matches the mold, unfold it in the mold cavity, and position it precisely. Using a casting device, evenly pour the inorganic composite slurry prepared with S1 into all the cells of the honeycomb core, supplementing the pouring with mechanical vibration at a frequency of 60 Hz for 20 seconds. After pouring, quickly lay a layer of 8 mm thick magnesium oxide board on both the upper and lower surfaces of the honeycomb core. Close the mold and send it into a flat vulcanizing machine.

[0052] A segmented pressurization process was used for molding: first, a pressure of 0.5 MPa was applied for pre-pressing for 1 minute. Then, the pressure was steadily increased to the final molding pressure of 1.5 MPa within 1 minute, while maintaining the hot plate temperature at 100°C. Under this set pressure and temperature, the material was held for curing for 10 minutes. After the pressure holding period, the pressure was released and the material was demolded to obtain a wet blank with a complete structure.

[0053] S4: Maintenance and Post-treatment After demolding, the wet sheet material is transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 95% for curing. The wet sheet material is placed horizontally on the curing rack, with a spacing of not less than 50 mm between the sheets. The standard curing time is 24 hours.

[0054] After curing, the boards are transferred to a drying oven for drying. The drying process is carried out at a constant temperature of 80℃ for 15 hours until the moisture content of the boards is below 10%. After drying, the boards are allowed to cool to room temperature and then cut to the required dimensions using a CNC cutting machine. The cut edges are then polished to obtain the finished thermal insulation, fireproof inorganic honeycomb board.

[0055] Comparative Example 1 The difference from Example 1 is that S1 uses only 70 parts of sulfoaluminate rapid-hardening cement, 30 parts of water and 1.5 parts of water-reducing agent to prepare pure cement slurry, completely omitting lightweight thermal insulation filler and flame-retardant fiber.

[0056] A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels, comprising the following steps: S1: Preparation of inorganic composite slurry Prepare materials according to the following proportions by weight: 70 parts sulfoaluminate rapid-hardening cement, 30 parts water, and 1.5 parts polycarboxylate superplasticizer.

[0057] First, pour the measured water into a planetary mixer and run it at a low speed of 80 rpm. Add the weighed water-reducing agent and mix for 2.5 minutes to ensure it is fully dissolved and dispersed. Then, add the weighed sulfoaluminate rapid-hardening cement and increase the mixing speed to 250 rpm, mixing for 4 minutes to form a homogeneous slurry base. Increase the mixing speed to 450 rpm and continue mixing for 6.5 minutes until a homogeneous paste-like composite slurry with no dry powder particles and appropriate viscosity and flowability is formed. The slurry should be used in subsequent processes within 30 minutes of preparation.

[0058] S2: Cellular Core Pretreatment A regular hexagonal paper honeycomb core with a side length of 8 mm was selected. Ammonium dihydrogen phosphate solid was dissolved in deionized water to prepare a 15% (w / w) flame retardant solution. The paper honeycomb core was completely immersed in the prepared flame retardant solution for 20 minutes, during which it could be gently turned to ensure complete immersion. After immersion, the honeycomb core was removed and placed on a draining rack to stand for 7 minutes to remove excess solution from the surface. It was then transferred to a circulating hot air drying oven and dried at 90°C for 2.5 hours until the moisture content of the honeycomb core was below 5%. The dried flame-retardant honeycomb core was then cooled in a dry environment for later use.

[0059] S3: One-piece molding Clean and preheat the upper and lower molds to 60°C. Take a flame-retardant honeycomb core that has been treated with S2 and whose size matches the mold, unfold it in the mold cavity, and position it precisely. Using a casting device, evenly pour the inorganic composite slurry prepared with S1 into all the cells of the honeycomb core. During pouring, supplement with mechanical vibration at a frequency of 50 Hz for 30 seconds to promote slurry flow and ensure dense filling. After pouring, quickly lay a 5 mm thick layer of asbestos-free fiber cement board on both the upper and lower surfaces of the honeycomb core. Close the mold and send it into a flat vulcanizing machine.

[0060] A segmented pressurization process was used for molding: first, a pressure of 0.35 MPa was applied for pre-pressing for 2 minutes. Then, the pressure was steadily increased to the final molding pressure of 1.0 MPa within 1 minute, while maintaining the hot plate temperature at 75°C. Under this set pressure and temperature, the material was held for curing for 25 minutes. After the pressure holding period, the pressure was released and the material was demolded to obtain a wet blank with a complete structure.

[0061] S4: Maintenance and Post-treatment After demolding, the wet sheet material is transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 95% for curing. The wet sheet material is placed horizontally on the curing rack, with a spacing of not less than 50 mm between the sheets. The standard curing time is 48 hours.

[0062] After curing, the boards are transferred to a drying oven for drying. The drying process involves increasing the temperature from 40°C to 65°C at a rate of 5°C / h, and maintaining this temperature at 65°C for 24 hours until the moisture content of the boards is below 10%. After drying, the boards are allowed to cool to room temperature and then cut to the required dimensions using a CNC cutting machine. The cut edges are then polished to obtain the finished thermal insulation, fireproof, inorganic honeycomb board.

[0063] Comparative Example 2 The difference from Example 1 is that ceramic fibers are removed in S1, and the amount of closed-cell expanded perlite is increased to 40 parts, while other components and proportions remain unchanged.

[0064] A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels, comprising the following steps: S1: Preparation of inorganic composite slurry Prepare the following materials by weight: 40 parts sulfoaluminate rapid-hardening cement, 40 parts closed-cell expanded perlite, 22.5 parts water, 1.5 parts polycarboxylate superplasticizer, 0.2 parts hydroxypropyl methylcellulose ether, and 0.1 parts silicone defoamer.

[0065] First, pour the measured water into a planetary mixer and run it at a low speed of 80 rpm. Add the weighed water-reducing agent, cellulose ether, and defoamer, and mix for 2.5 minutes to ensure they are fully dissolved and dispersed. Then, add the weighed sulfoaluminate rapid-hardening cement and increase the mixing speed to 250 rpm, mixing for 4 minutes to form a homogeneous slurry base. Finally, while maintaining mixing, gradually add the weighed closed-cell expanded perlite. After all materials have been added, increase the mixing speed to 450 rpm and continue mixing for 6.5 minutes until a homogeneous paste-like composite slurry with no dry powder particles and appropriate viscosity and flowability is formed. The slurry should be used in subsequent processes within 30 minutes of preparation.

[0066] S2: Cellular Core Pretreatment A regular hexagonal paper honeycomb core with a side length of 8 mm was selected. Ammonium dihydrogen phosphate solid was dissolved in deionized water to prepare a 15% (w / w) flame retardant solution. The paper honeycomb core was completely immersed in the prepared flame retardant solution for 20 minutes, during which it could be gently turned to ensure complete immersion. After immersion, the honeycomb core was removed and placed on a draining rack to stand for 7 minutes to remove excess solution from the surface. It was then transferred to a circulating hot air drying oven and dried at 90°C for 2.5 hours until the moisture content of the honeycomb core was below 5%. The dried flame-retardant honeycomb core was then cooled in a dry environment for later use.

[0067] S3: One-piece molding Clean and preheat the upper and lower molds to 60°C. Take a flame-retardant honeycomb core that has been treated with S2 and whose size matches the mold, unfold it in the mold cavity, and position it precisely. Using a casting device, evenly pour the inorganic composite slurry prepared with S1 into all the cells of the honeycomb core. During pouring, supplement with mechanical vibration at a frequency of 50 Hz for 30 seconds to promote slurry flow and ensure dense filling. After pouring, quickly lay a 5 mm thick layer of asbestos-free fiber cement board on both the upper and lower surfaces of the honeycomb core. Close the mold and send it into a flat vulcanizing machine.

[0068] A segmented pressurization process was used for molding: first, a pressure of 0.35 MPa was applied for pre-pressing for 2 minutes. Then, the pressure was steadily increased to the final molding pressure of 1.0 MPa within 1 minute, while maintaining the hot plate temperature at 75°C. Under this set pressure and temperature, the material was held for curing for 25 minutes. After the pressure holding period, the pressure was released and the material was demolded to obtain a wet blank with a complete structure.

[0069] S4: Maintenance and Post-treatment After demolding, the wet sheet material is transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 95% for curing. The wet sheet material is placed horizontally on the curing rack, with a spacing of not less than 50 mm between the sheets. The standard curing time is 48 hours.

[0070] After curing, the boards are transferred to a drying oven for drying. The drying process involves increasing the temperature from 40°C to 65°C at a rate of 5°C / h, and maintaining this temperature at 65°C for 24 hours until the moisture content of the boards is below 10%. After drying, the boards are allowed to cool to room temperature and then cut to the required dimensions using a CNC cutting machine. The cut edges are then polished to obtain the finished thermal insulation, fireproof, inorganic honeycomb board.

[0071] Comparative Example 3 The difference from Example 1 is that S3 is changed to a step-by-step operation: first, the grout is poured to form a solid slab and cured; then, epoxy resin structural adhesive is used to bond the slab to the treated honeycomb core and panel, and pressure is applied for curing.

[0072] A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels, comprising the following steps: S1: Preparation of inorganic composite slurry Prepare materials by weight: 40 parts sulfoaluminate rapid-hardening cement, 30 parts closed-cell expanded perlite, 10 parts ceramic fiber, 22.5 parts water, 1.5 parts polycarboxylate superplasticizer, 0.2 parts hydroxypropyl methylcellulose ether, and 0.1 parts silicone defoamer.

[0073] First, pour the measured water into a planetary mixer and run it at a low speed of 80 rpm. Add the weighed water-reducing agent, cellulose ether, and defoamer, and mix for 2.5 minutes to ensure they are fully dissolved and dispersed. Then, add the weighed sulfoaluminate rapid-hardening cement and increase the mixing speed to 250 rpm, mixing for 4 minutes to form a homogeneous slurry base. Finally, while maintaining mixing, gradually add the weighed closed-cell expanded perlite and ceramic fibers. After all materials have been added, increase the mixing speed to 450 rpm and continue mixing for 6.5 minutes until a homogeneous paste-like composite slurry with no dry powder particles and appropriate viscosity and flowability is formed. The slurry should be used in subsequent processes within 30 minutes of preparation.

[0074] S2: Cellular Core Pretreatment A regular hexagonal paper honeycomb core with a side length of 8 mm was selected. Ammonium dihydrogen phosphate solid was dissolved in deionized water to prepare a 15% (w / w) flame retardant solution. The paper honeycomb core was completely immersed in the prepared flame retardant solution for 20 minutes, during which it could be gently turned to ensure complete immersion. After immersion, the honeycomb core was removed and placed on a draining rack to stand for 7 minutes to remove excess solution from the surface. It was then transferred to a circulating hot air drying oven and dried at 90°C for 2.5 hours until the moisture content of the honeycomb core was below 5%. The dried flame-retardant honeycomb core was then cooled in a dry environment for later use.

[0075] S3: Step-by-step molding and composite Inorganic solid slab blanks were prepared. The inorganic composite slurry prepared in S1 was poured into a mold cavity with a smooth surface, with a pouring thickness of 5 mm. The mold was placed on a vibration table and vibrated at a frequency of 50 Hz for 30 seconds to remove air bubbles and level the surface. The mold was then placed in a curing chamber and cured at 75℃ and normal pressure for 25 min. After demolding, a solid inorganic slab blank was obtained. The slab blank was then transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 95% for further curing for 48 h.

[0076] Structural bonding and assembly. Take a flame-retardant honeycomb core treated with S2, and evenly coat both its upper and lower surfaces with a two-component epoxy structural adhesive at a coating weight of 300 g / m². 2Two inorganic solid slabs prepared using S3-1 were respectively placed on both sides of the glued honeycomb core to form a "panel-adhesive layer-core material-adhesive layer-panel" structure. This assembly was placed in a cold press and subjected to a pressure of 0.1 MPa at ambient temperature for 24 hours to allow the adhesive to fully cure and form an adhesive layer. After bonding and curing were completed, the pressure was released and the composite board was removed, yielding the comparison board blank.

[0077] S4: Maintenance and Post-treatment After demolding, the wet sheet material is transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 95% for curing. The wet sheet material is placed horizontally on the curing rack, with a spacing of not less than 50 mm between the sheets. The standard curing time is 48 hours.

[0078] After curing, the boards are transferred to a drying oven for drying. The drying process involves increasing the temperature from 40°C to 65°C at a rate of 5°C / h, and maintaining this temperature at 65°C for 24 hours until the moisture content of the boards is below 10%. After drying, the boards are allowed to cool to room temperature and then cut to the required dimensions using a CNC cutting machine. The cut edges are then polished to obtain the finished thermal insulation, fireproof, inorganic honeycomb board.

[0079] Comparative Example 4 The difference from Example 1 is that the ammonium dihydrogen phosphate solution impregnation step is omitted in S2, and only the paper honeycomb is dried under the same conditions.

[0080] A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels, comprising the following steps: S1: Preparation of inorganic composite slurry Prepare materials by weight: 40 parts sulfoaluminate rapid-hardening cement, 30 parts closed-cell expanded perlite, 10 parts ceramic fiber, 22.5 parts water, 1.5 parts polycarboxylate superplasticizer, 0.2 parts hydroxypropyl methylcellulose ether, and 0.1 parts silicone defoamer.

[0081] First, pour the measured water into a planetary mixer and run it at a low speed of 80 rpm. Add the weighed water-reducing agent, cellulose ether, and defoamer, and mix for 2.5 minutes to ensure they are fully dissolved and dispersed. Then, add the weighed sulfoaluminate rapid-hardening cement and increase the mixing speed to 250 rpm, mixing for 4 minutes to form a homogeneous slurry base. Finally, while maintaining mixing, gradually add the weighed closed-cell expanded perlite and ceramic fibers. After all materials have been added, increase the mixing speed to 450 rpm and continue mixing for 6.5 minutes until a homogeneous paste-like composite slurry with no dry powder particles and appropriate viscosity and flowability is formed. The slurry should be used in subsequent processes within 30 minutes of preparation.

[0082] S2: Cellular Core Pretreatment Select regular hexagonal paper honeycomb with a side length of 8 mm. Transfer it to a circulating hot air drying oven and dry it at 90°C for 2.5 hours until the moisture content of the honeycomb core is less than 5%. Place the dried flame-retardant honeycomb core in a dry environment to cool and store for later use.

[0083] S3: One-piece molding Clean and preheat the upper and lower molds to 60°C. Take a flame-retardant honeycomb core that has been treated with S2 and whose size matches the mold, unfold it in the mold cavity, and position it precisely. Using a casting device, evenly pour the inorganic composite slurry prepared with S1 into all the cells of the honeycomb core. During pouring, supplement with mechanical vibration at a frequency of 50 Hz for 30 seconds to promote slurry flow and ensure dense filling. After pouring, quickly lay a 5 mm thick layer of asbestos-free fiber cement board on both the upper and lower surfaces of the honeycomb core. Close the mold and send it into a flat vulcanizing machine.

[0084] A segmented pressurization process was used for molding: first, a pressure of 0.35 MPa was applied for pre-pressing for 2 minutes. Then, the pressure was steadily increased to the final molding pressure of 1.0 MPa within 1 minute, while maintaining the hot plate temperature at 75°C. Under this set pressure and temperature, the material was held for curing for 25 minutes. After the pressure holding period, the pressure was released and the material was demolded to obtain a wet blank with a complete structure.

[0085] S4: Maintenance and Post-treatment After demolding, the wet sheet material is transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 95% for curing. The wet sheet material is placed horizontally on the curing rack, with a spacing of not less than 50 mm between the sheets. The standard curing time is 48 hours.

[0086] After curing, the boards are transferred to a drying oven for drying. The drying process involves increasing the temperature from 40°C to 65°C at a rate of 5°C / h, and maintaining this temperature at 65°C for 24 hours until the moisture content of the boards is below 10%. After drying, the boards are allowed to cool to room temperature and then cut to the required dimensions using a CNC cutting machine. The cut edges are then polished to obtain the finished thermal insulation, fireproof, inorganic honeycomb board.

[0087] Comparative Example 5 The difference from Example 1 is that in S1, all inorganic cementing materials are replaced with an equal amount of high-strength gypsum. Because its setting time and water requirement are different, the water is adjusted to 28 parts, and 0.5 parts of citric acid retarder are added. A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels, comprising the following steps: S1: Preparation of inorganic composite slurry Prepare the following materials by weight: 40 parts high-strength gypsum, 30 parts closed-cell expanded perlite, 10 parts ceramic fiber, 28 parts water, 1.5 parts polycarboxylate superplasticizer, 0.2 parts hydroxypropyl methylcellulose ether, 0.1 parts silicone defoamer, and 0.5 parts citric acid retarder.

[0088] First, pour the measured water into a planetary mixer and run it at a low speed of 80 rpm. Add the weighed water-reducing agent, cellulose ether, defoamer, and citric acid retarder, and stir for 2.5 minutes to ensure complete dissolution and dispersion. Next, add the weighed high-strength gypsum and increase the stirring speed to 250 rpm, stirring for 4 minutes to form a homogeneous slurry base. Finally, while maintaining stirring, gradually add the weighed closed-cell expanded perlite and ceramic fibers. After all materials have been added, increase the stirring speed to 450 rpm and continue stirring for 6.5 minutes until a homogeneous, dry powder-free, paste-like composite slurry with appropriate viscosity and flowability is formed. The slurry should be used in subsequent processes within 30 minutes of preparation.

[0089] S2: Cellular Core Pretreatment A regular hexagonal paper honeycomb core with a side length of 8 mm was selected. Ammonium dihydrogen phosphate solid was dissolved in deionized water to prepare a 15% (w / w) flame retardant solution. The paper honeycomb core was completely immersed in the prepared flame retardant solution for 20 minutes, during which it could be gently turned to ensure complete immersion. After immersion, the honeycomb core was removed and placed on a draining rack to stand for 7 minutes to remove excess solution from the surface. It was then transferred to a circulating hot air drying oven and dried at 90°C for 2.5 hours until the moisture content of the honeycomb core was below 5%. The dried flame-retardant honeycomb core was then cooled in a dry environment for later use.

[0090] S3: One-piece molding Clean and preheat the upper and lower molds to 60°C. Take a flame-retardant honeycomb core that has been treated with S2 and whose size matches the mold, unfold it in the mold cavity, and position it precisely. Using a casting device, evenly pour the inorganic composite slurry prepared with S1 into all the cells of the honeycomb core. During pouring, supplement with mechanical vibration at a frequency of 50 Hz for 30 seconds to promote slurry flow and ensure dense filling. After pouring, quickly lay a 5 mm thick layer of asbestos-free fiber cement board on both the upper and lower surfaces of the honeycomb core. Close the mold and send it into a flat vulcanizing machine.

[0091] A segmented pressurization process was used for molding: first, a pressure of 0.35 MPa was applied for pre-pressing for 2 minutes. Then, the pressure was steadily increased to the final molding pressure of 1.0 MPa within 1 minute, while maintaining the hot plate temperature at 75°C. Under this set pressure and temperature, the material was held for curing for 25 minutes. After the pressure holding period, the pressure was released and the material was demolded to obtain a wet blank with a complete structure.

[0092] S4: Maintenance and Post-treatment After demolding, the wet sheet material is transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 95% for curing. The wet sheet material is placed horizontally on the curing rack, with a spacing of not less than 50 mm between the sheets. The standard curing time is 48 hours.

[0093] After curing, the boards are transferred to a drying oven for drying. The drying process involves increasing the temperature from 40°C to 65°C at a rate of 5°C / h, and maintaining this temperature at 65°C for 24 hours until the moisture content of the boards is below 10%. After drying, the boards are allowed to cool to room temperature and then cut to the required dimensions using a CNC cutting machine. The cut edges are then polished to obtain the finished thermal insulation, fireproof, inorganic honeycomb board.

[0094] Comparative Example 6 The difference from Example 1 is that the molding step is omitted in S3. After the slurry is poured into the mold containing the honeycomb core and panel, it is simply left to stand and smoothed, and then cured at normal pressure and 75°C for 25 minutes.

[0095] A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels, comprising the following steps: S1: Preparation of inorganic composite slurry Prepare materials by weight: 40 parts sulfoaluminate rapid-hardening cement, 30 parts closed-cell expanded perlite, 10 parts ceramic fiber, 22.5 parts water, 1.5 parts polycarboxylate superplasticizer, 0.2 parts hydroxypropyl methylcellulose ether, and 0.1 parts silicone defoamer.

[0096] First, pour the measured water into a planetary mixer and run it at a low speed of 80 rpm. Add the weighed water-reducing agent, cellulose ether, and defoamer, and mix for 2.5 minutes to ensure they are fully dissolved and dispersed. Then, add the weighed sulfoaluminate rapid-hardening cement and increase the mixing speed to 250 rpm, mixing for 4 minutes to form a homogeneous slurry base. Finally, while maintaining mixing, gradually add the weighed closed-cell expanded perlite and ceramic fibers. After all materials have been added, increase the mixing speed to 450 rpm and continue mixing for 6.5 minutes until a homogeneous paste-like composite slurry with no dry powder particles and appropriate viscosity and flowability is formed. The slurry should be used in subsequent processes within 30 minutes of preparation.

[0097] S2: Cellular Core Pretreatment A regular hexagonal paper honeycomb core with a side length of 8 mm was selected. Ammonium dihydrogen phosphate solid was dissolved in deionized water to prepare a 15% (w / w) flame retardant solution. The paper honeycomb core was completely immersed in the prepared flame retardant solution for 20 minutes, during which it could be gently turned to ensure complete immersion. After immersion, the honeycomb core was removed and placed on a draining rack to stand for 7 minutes to remove excess solution from the surface. It was then transferred to a circulating hot air drying oven and dried at 90°C for 2.5 hours until the moisture content of the honeycomb core was below 5%. The dried flame-retardant honeycomb core was then cooled in a dry environment for later use.

[0098] S3: Static curing molding Clean the upper and lower molds and preheat them to 60°C. Take a flame-retardant honeycomb core that has been treated with S2 and whose size matches the mold, unfold it in the mold cavity, and position it precisely. Using a casting device, evenly pour the inorganic composite slurry prepared with S1 into all the cells of the honeycomb core. During casting, supplement with mechanical vibration at a frequency of 50 Hz for 30 seconds to promote slurry flow and ensure dense filling. After casting, quickly lay a 5 mm thick layer of asbestos-free fiber cement board on both the upper and lower surfaces of the honeycomb core, then close the mold cover without applying external clamping pressure.

[0099] After molding, the entire mold is transferred to a constant temperature curing chamber and cured for 25 minutes at normal pressure and 75°C. During this process, the slurry remains within the honeycomb cells solely due to its own gravity and capillary action, completing the initial setting and hardening. After the curing time is complete, the mold is removed and manually demolded to obtain a pre-formed board blank.

[0100] S4: Maintenance and Post-treatment After demolding, the wet sheet material is transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 95% for curing. The wet sheet material is placed horizontally on the curing rack, with a spacing of not less than 50 mm between the sheets. The standard curing time is 48 hours.

[0101] After curing, the boards are transferred to a drying oven for drying. The drying process involves increasing the temperature from 40°C to 65°C at a rate of 5°C / h, and maintaining this temperature at 65°C for 24 hours until the moisture content of the boards is below 10%. After drying, the boards are allowed to cool to room temperature and then cut to the required dimensions using a CNC cutting machine. The cut edges are then polished to obtain the finished thermal insulation, fireproof, inorganic honeycomb board.

[0102] Comparative Example 7 The difference from Example 1 is that in S3, the final molding pressure is reduced to 0.4 MPa.

[0103] A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels, comprising the following steps: S1: Preparation of inorganic composite slurry Prepare materials by weight: 40 parts sulfoaluminate rapid-hardening cement, 30 parts closed-cell expanded perlite, 10 parts ceramic fiber, 22.5 parts water, 1.5 parts polycarboxylate superplasticizer, 0.2 parts hydroxypropyl methylcellulose ether, and 0.1 parts silicone defoamer.

[0104] First, pour the measured water into a planetary mixer and run it at a low speed of 80 rpm. Add the weighed water-reducing agent, cellulose ether, and defoamer, and mix for 2.5 minutes to ensure they are fully dissolved and dispersed. Then, add the weighed sulfoaluminate rapid-hardening cement and increase the mixing speed to 250 rpm, mixing for 4 minutes to form a homogeneous slurry base. Finally, while maintaining mixing, gradually add the weighed closed-cell expanded perlite and ceramic fibers. After all materials have been added, increase the mixing speed to 450 rpm and continue mixing for 6.5 minutes until a homogeneous paste-like composite slurry with no dry powder particles and appropriate viscosity and flowability is formed. The slurry should be used in subsequent processes within 30 minutes of preparation.

[0105] S2: Cellular Core Pretreatment A regular hexagonal paper honeycomb core with a side length of 8 mm was selected. Ammonium dihydrogen phosphate solid was dissolved in deionized water to prepare a 15% (w / w) flame retardant solution. The paper honeycomb core was completely immersed in the prepared flame retardant solution for 20 minutes, during which it could be gently turned to ensure complete immersion. After immersion, the honeycomb core was removed and placed on a draining rack to stand for 7 minutes to remove excess solution from the surface. It was then transferred to a circulating hot air drying oven and dried at 90°C for 2.5 hours until the moisture content of the honeycomb core was below 5%. The dried flame-retardant honeycomb core was then cooled in a dry environment for later use.

[0106] S3: One-piece molding Clean and preheat the upper and lower molds to 60°C. Take a flame-retardant honeycomb core that has been treated with S2 and whose size matches the mold, unfold it in the mold cavity, and position it precisely. Using a casting device, evenly pour the inorganic composite slurry prepared with S1 into all the cells of the honeycomb core. During pouring, supplement with mechanical vibration at a frequency of 50 Hz for 30 seconds to promote slurry flow and ensure dense filling. After pouring, quickly lay a 5 mm thick layer of asbestos-free fiber cement board on both the upper and lower surfaces of the honeycomb core. Close the mold and send it into a flat vulcanizing machine.

[0107] A segmented pressurization process was used for molding: first, a pressure of 0.35 MPa was applied for pre-pressing for 2 minutes. Then, the pressure was steadily increased to the final molding pressure of 0.4 MPa within 1 minute, while maintaining the hot plate temperature at 75°C. Under this set pressure and temperature, the material was held for curing for 25 minutes. After the pressure holding period, the pressure was released and the material was demolded to obtain a wet blank with a complete structure.

[0108] S4: Maintenance and Post-treatment After demolding, the wet sheet material is transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 95% for curing. The wet sheet material is placed horizontally on the curing rack, with a spacing of not less than 50 mm between the sheets. The standard curing time is 48 hours.

[0109] After curing, the boards are transferred to a drying oven for drying. The drying process involves increasing the temperature from 40°C to 65°C at a rate of 5°C / h, and maintaining this temperature at 65°C for 24 hours until the moisture content of the boards is below 10%. After drying, the boards are allowed to cool to room temperature and then cut to the required dimensions using a CNC cutting machine. The cut edges are then polished to obtain the finished thermal insulation, fireproof, inorganic honeycomb board.

[0110] Comparative Example 8 The difference from Example 1 is that in S1, the amount of closed-cell expanded perlite is increased to 50 parts, and the amount of sulfoaluminate rapid-hardening cement is reduced to 20 parts.

[0111] A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels, comprising the following steps: S1: Preparation of inorganic composite slurry Prepare materials by weight: 20 parts sulfoaluminate rapid-hardening cement, 50 parts closed-cell expanded perlite, 10 parts ceramic fiber, 22.5 parts water, 1.5 parts polycarboxylate superplasticizer, 0.2 parts hydroxypropyl methylcellulose ether, and 0.1 parts silicone defoamer.

[0112] First, pour the measured water into a planetary mixer and run it at a low speed of 80 rpm. Add the weighed water-reducing agent, cellulose ether, and defoamer, and mix for 2.5 minutes to ensure they are fully dissolved and dispersed. Then, add the weighed sulfoaluminate rapid-hardening cement and increase the mixing speed to 250 rpm, mixing for 4 minutes to form a homogeneous slurry base. Finally, while maintaining mixing, gradually add the weighed closed-cell expanded perlite and ceramic fibers. After all materials have been added, increase the mixing speed to 450 rpm and continue mixing for 6.5 minutes until a homogeneous paste-like composite slurry with no dry powder particles and appropriate viscosity and flowability is formed. The slurry should be used in subsequent processes within 30 minutes of preparation.

[0113] S2: Cellular Core Pretreatment A regular hexagonal paper honeycomb core with a side length of 8 mm was selected. Ammonium dihydrogen phosphate solid was dissolved in deionized water to prepare a 15% (w / w) flame retardant solution. The paper honeycomb core was completely immersed in the prepared flame retardant solution for 20 minutes, during which it could be gently turned to ensure complete immersion. After immersion, the honeycomb core was removed and placed on a draining rack to stand for 7 minutes to remove excess solution from the surface. It was then transferred to a circulating hot air drying oven and dried at 90°C for 2.5 hours until the moisture content of the honeycomb core was below 5%. The dried flame-retardant honeycomb core was then cooled in a dry environment for later use.

[0114] S3: One-piece molding Clean and preheat the upper and lower molds to 60°C. Take a flame-retardant honeycomb core that has been treated with S2 and whose size matches the mold, unfold it in the mold cavity, and position it precisely. Using a casting device, evenly pour the inorganic composite slurry prepared with S1 into all the cells of the honeycomb core. During pouring, supplement with mechanical vibration at a frequency of 50 Hz for 30 seconds to promote slurry flow and ensure dense filling. After pouring, quickly lay a 5 mm thick layer of asbestos-free fiber cement board on both the upper and lower surfaces of the honeycomb core. Close the mold and send it into a flat vulcanizing machine.

[0115] A segmented pressurization process was used for molding: first, a pressure of 0.35 MPa was applied for pre-pressing for 2 minutes. Then, the pressure was steadily increased to the final molding pressure of 1.0 MPa within 1 minute, while maintaining the hot plate temperature at 75°C. Under this set pressure and temperature, the material was held for curing for 25 minutes. After the pressure holding period, the pressure was released and the material was demolded to obtain a wet blank with a complete structure.

[0116] S4: Maintenance and Post-treatment After demolding, the wet sheet material is transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 95% for curing. The wet sheet material is placed horizontally on the curing rack, with a spacing of not less than 50 mm between the sheets. The standard curing time is 48 hours.

[0117] After curing, the boards are transferred to a drying oven for drying. The drying process involves increasing the temperature from 40°C to 65°C at a rate of 5°C / h, and maintaining this temperature at 65°C for 24 hours until the moisture content of the boards is below 10%. After drying, the boards are allowed to cool to room temperature and then cut to the required dimensions using a CNC cutting machine. The cut edges are then polished to obtain the finished thermal insulation, fireproof, inorganic honeycomb board.

[0118] Comparative Example 9 The difference from Example 1 is that in S3, the asbestos-free fiber cement panel is replaced with a flame-retardant polymer plastic panel of the same thickness.

[0119] A process for integral molding of thermal insulation and fireproof inorganic honeycomb panels, comprising the following steps: S1: Preparation of inorganic composite slurry Prepare materials by weight: 40 parts sulfoaluminate rapid-hardening cement, 30 parts closed-cell expanded perlite, 10 parts ceramic fiber, 22.5 parts water, 1.5 parts polycarboxylate superplasticizer, 0.2 parts hydroxypropyl methylcellulose ether, and 0.1 parts silicone defoamer.

[0120] First, pour the measured water into a planetary mixer and run it at a low speed of 80 rpm. Add the weighed water-reducing agent, cellulose ether, and defoamer, and mix for 2.5 minutes to ensure they are fully dissolved and dispersed. Then, add the weighed sulfoaluminate rapid-hardening cement and increase the mixing speed to 250 rpm, mixing for 4 minutes to form a homogeneous slurry base. Finally, while maintaining mixing, gradually add the weighed closed-cell expanded perlite and ceramic fibers. After all materials have been added, increase the mixing speed to 450 rpm and continue mixing for 6.5 minutes until a homogeneous paste-like composite slurry with no dry powder particles and appropriate viscosity and flowability is formed. The slurry should be used in subsequent processes within 30 minutes of preparation.

[0121] S2: Cellular Core Pretreatment A regular hexagonal paper honeycomb core with a side length of 8 mm was selected. Ammonium dihydrogen phosphate solid was dissolved in deionized water to prepare a 15% (w / w) flame retardant solution. The paper honeycomb core was completely immersed in the prepared flame retardant solution for 20 minutes, during which it could be gently turned to ensure complete immersion. After immersion, the honeycomb core was removed and placed on a draining rack to stand for 7 minutes to remove excess solution from the surface. It was then transferred to a circulating hot air drying oven and dried at 90°C for 2.5 hours until the moisture content of the honeycomb core was below 5%. The dried flame-retardant honeycomb core was then cooled in a dry environment for later use.

[0122] S3: One-piece molding Clean the upper and lower molds and preheat them to 60℃. Take a flame-retardant honeycomb core that has been treated with S2 and whose size matches the mold, unfold it in the mold cavity, and position it precisely. Using a casting device, evenly pour the inorganic composite slurry prepared with S1 into all the cells of the honeycomb core. During casting, supplement with mechanical vibration at a frequency of 50 Hz for 30 seconds to promote slurry flow and ensure dense filling. After casting, quickly lay a 5 mm thick layer of flame-retardant polymer plastic sheet on both the upper and lower surfaces of the honeycomb core. Close the mold and send it into a flat vulcanizing machine.

[0123] A segmented pressurization process was used for molding: first, a pressure of 0.35 MPa was applied for pre-pressing for 2 minutes. Then, the pressure was steadily increased to the final molding pressure of 1.0 MPa within 1 minute, while maintaining the hot plate temperature at 75°C. Under this set pressure and temperature, the material was held for curing for 25 minutes. After the pressure holding period, the pressure was released and the material was demolded to obtain a wet blank with a complete structure.

[0124] S4: Maintenance and Post-treatment After demolding, the wet sheet material is transferred to a standard curing room with a temperature controlled at 20±2℃ and a relative humidity of not less than 95% for curing. The wet sheet material is placed horizontally on the curing rack, with a spacing of not less than 50 mm between the sheets. The standard curing time is 48 hours.

[0125] After curing, the boards are transferred to a drying oven for drying. The drying process involves increasing the temperature from 40°C to 65°C at a rate of 5°C / h, and maintaining this temperature at 65°C for 24 hours until the moisture content of the boards is below 10%. After drying, the boards are allowed to cool to room temperature and then cut to the required dimensions using a CNC cutting machine. The cut edges are then polished to obtain the finished thermal insulation, fireproof, inorganic honeycomb board.

[0126] The detection methods are shown in Table 1:

[0127]

[0128] The technical background addressed by this invention lies in the fact that traditional inorganic honeycomb panels, due to their discrete composite processes and single material systems, have long suffered from inherent defects such as weak interlayer bonding, easy deformation of the honeycomb core, and inconsistent fire resistance between the core material and the surface layer. To systematically overcome these bottlenecks, this invention proposes a synergistic solution integrating a specific inorganic composite slurry, an intrinsically flame-retardant honeycomb core, and a molding process. Analysis of test data from examples and comparative studies clearly demonstrates the theoretical mechanism of this solution through its performance advantages and variation patterns. Of all the embodiments, Embodiment 1 exhibits the best overall performance balance, thanks to the appropriate ratio of cementitious materials, lightweight fillers, and flame-retardant fibers in its composite slurry, which provides the system with a stable skeleton, an efficient thermal insulation barrier, and a tough network at high temperatures. By deeply impregnating the honeycomb core with inorganic flame retardants, the combustion hazard of organic core materials is fundamentally eliminated. Most importantly, the molding process, under the combined action of heat and force, promotes the formation of a uniform and firm overall bonding interface between the slurry, honeycomb core, and panel, which is dominated by mechanical interlocking, thereby preventing interlayer delamination at the source and stabilizing the structural morphology.

[0129] In contrast, the performance shortcomings of each comparative example all stemmed from the disruption or weakening of a key element in the aforementioned synergistic system. Specifically, Comparative Example 1 used pure cement slurry, which, while possessing acceptable strength, resulted in an overly dense and heavy system. Furthermore, due to the lack of fiber toughening and filler adjustment, its interface with the porous core material was inherently weak. Comparative Example 2 omitted flame-retardant fibers, leading to decreased matrix toughness and increased susceptibility to microcracks under stress or thermal shock. Comparative Example 3 reverted to the traditional adhesive bonding approach, with its reliance on an organic adhesive layer becoming a weak point in weather resistance and high-temperature resistance, significantly deteriorating the interfacial bonding strength. Comparative Example 4 failed to treat the honeycomb core with flame retardants, exposing the flammable core material to the threat of fire and completely compromising the overall fire safety of the board. Comparative Example 5 used pure gypsum-based cementitious materials, whose poor water resistance and slow strength development characteristics were difficult to match with the continuous molding process and long-term durability requirements. Comparative Example 6 completely eliminated the molding step, preventing the slurry from achieving dense filling and tight bonding within the core material's pores, resulting in a loose overall structure and a severe decline in various mechanical properties. Comparative Example 7's insufficient molding pressure also led to inadequate bonding between the slurry and reinforcement, failing to fully utilize interfacial performance. Comparative Example 8 excessively added lightweight fillers at the expense of the cementitious skeleton, severely weakening the matrix structure's strength. Comparative Example 9 used an organic polymer panel, which not only posed a deformation risk during high-temperature molding but, more importantly, significantly reduced the system's overall fire resistance rating. In summary, the superiority of Example 1 and the performance degradation patterns of the comparative examples collectively demonstrate that the technical effectiveness of this invention does not stem from the simple superposition of single materials or steps, but rather relies on the inseparable synergistic effect of the inorganic composite system design, the inherent flame-retardant modification of the core material, and the integrated molding process. This is the fundamental reason why it can systematically solve traditional pain points in the industry.

Claims

1. A process for integrally molding and manufacturing thermal insulation and fireproof inorganic honeycomb panels, characterized in that, Includes the following steps: S1. Preparation of inorganic composite slurry: Inorganic cementitious materials, lightweight thermal insulation fillers, flame-retardant fibers, water and optional additives are mixed and stirred evenly to obtain inorganic composite slurry; S2. Pretreatment of honeycomb core: The paper honeycomb is immersed in a flame retardant solution and then dried to obtain a flame retardant honeycomb core; S3. Integrated molding: The flame-retardant honeycomb core obtained in step S2 is unfolded and positioned in the mold. Then, the inorganic composite slurry obtained in step S1 is poured into the cells of the flame-retardant honeycomb core. Panel material is laid on the upper and lower surfaces of the flame-retardant honeycomb core. Then, it is sent into a molding press for integrated molding. S4. Curing and post-processing: Demold the molded blank, then perform standard curing, drying and dimensional processing to obtain the heat-insulating, fireproof inorganic honeycomb board.

2. The integrated molding process for thermal insulation and fireproof inorganic honeycomb panels according to claim 1, characterized in that, In step S1, the inorganic composite slurry comprises, by mass parts: 30-50 parts inorganic cementitious material, 20-40 parts lightweight thermal insulation filler, 5-15 parts flame retardant fiber, 15-30 parts water, and 0.5-3 parts additives.

3. The integrated molding process for thermal insulation and fireproof inorganic honeycomb panels according to claim 2, characterized in that, The inorganic cementitious material is at least one of sulfoaluminate rapid-hardening cement, ferroaluminate cement, high-alumina cement, desulfurized gypsum, and high-strength gypsum; the lightweight thermal insulation filler is at least one of expanded perlite, vitrified microspheres, closed-cell expanded perlite, cenospheres, and ceramic sand.

4. The integrated molding process for thermal insulation and fireproof inorganic honeycomb panels according to claim 2, characterized in that, The flame-retardant fiber is at least one of ceramic fiber, basalt fiber, glass fiber, mineral wool fiber, and aramid pulp; the additive is at least one of water-reducing agent, retarder, accelerator, water-retaining agent, thickener, and defoamer.

5. The integrated molding process for thermal insulation and fireproof inorganic honeycomb panels according to claim 1, characterized in that, In step S2, the flame retardant solution is at least one of ammonium dihydrogen phosphate solution, ammonium polyphosphate solution, zinc borate solution, and borax solution, with a mass concentration of 5%-25%; the drying temperature is 60℃-120℃, and the honeycomb core is dried until the moisture content is less than 5%.

6. The integrated molding process for thermal insulation and fireproof inorganic honeycomb panels according to claim 1, characterized in that, In step S3, the panel material is asbestos-free fiber cement board, calcium silicate board, magnesium oxide board, magnesium oxide board, aluminum foil, or metal sheet.

7. The integrated molding process for thermal insulation and fireproof inorganic honeycomb panels according to claim 1, characterized in that, In step S3, the process parameters for the integrated molding are: molding pressure 0.5MPa-1.5MPa, molding temperature 50℃-100℃, and holding time 10min-40min.

8. The integrated molding process for thermal insulation and fireproof inorganic honeycomb panels according to claim 7, characterized in that, In the integrated molding process, a segmented pressurization system is adopted: first, pre-pressurize at 0.2MPa-0.5MPa for 1min-3min, then increase to the molding pressure and maintain the pressure for the specified holding time.

9. The integrated molding process for thermal insulation and fireproof inorganic honeycomb panels according to claim 1, characterized in that, In step S4, the standard curing conditions are: temperature 20±2℃, relative humidity above 90%, and curing time of 24h-72h; the drying treatment temperature is 40℃-80℃, and the drying is carried out until the moisture content of the board is below 10%.

10. A thermally insulating and fire-resistant inorganic honeycomb panel prepared by the integral molding process of any one of claims 1 to 9, characterized in that, It uses paper honeycomb treated with flame retardant solution as core material. The core material's pores and upper and lower surfaces are integrally molded with a matrix and panel material formed by inorganic cementitious materials, lightweight thermal insulation fillers and flame retardant fibers.

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