Diatom inorganic A1-grade mineral board, fireproof suspended ceiling and installation method of fireproof suspended ceiling

Abstract

The invention relates to the field of building construction, in particular to a diatom inorganic A1-grade mineral board, a fireproof suspended ceiling and an installation method thereof.On the basis that diatom serves as a main body, sulphoaluminate cement serves as a colloidal main body, a cross-linked network structure is formed through sepiolite fibers and tetrapod-like zinc oxide whiskers, the humidity adjusting performance of a system is not affected, and meanwhile the fireproof suspended ceiling is made of inorganic diatom inorganic A1-grade mineral boards; the good moisture-proof performance of the system is guaranteed, the toughness is improved on the whole, and the wet expansion and dry shrinkage are reduced, so that the composite material is used as a suspended ceiling or other home decoration materials, and good performance and long quality guarantee are provided.

Description

Technical Field

[0001] This application relates to the field of building construction, and in particular to a diatomaceous inorganic A1 grade mineral board, a fireproof ceiling and its installation method. Background Technology

[0002] In the interior decoration of public buildings and high-end residences, the fire safety and construction efficiency of suspended ceilings are crucial considerations. Currently, the conventional ceiling material is usually gypsum board, but its fire resistance is typically only B1, posing a certain fire hazard. Furthermore, its high density and brittleness can easily affect the long-term stability of the ceiling system. Additionally, gypsum board itself has poor adhesion to coatings, requiring additional alignment and plastering to improve coating smoothness, which further increases the weight of the ceiling.

[0003] Diatomaceous earth inorganic mineral board is a new type of environmentally friendly building material made from diatomaceous earth as the core raw material, supplemented with inorganic materials such as fiberglass and calcium powder, and formed by high-temperature pressing. In this system, the unique porous structure and inorganic properties of diatomaceous earth endow it with integrated functions such as air purification, fire resistance, sound insulation, and heat insulation, and it has broad prospects in the future market.

[0004] Despite the many advantages of diatomaceous earth and inorganic fibers, there are still some problems in the system. Diatomaceous earth itself has a lot of pore structure, which makes it very easy to absorb moisture. After absorbing moisture, it is prone to swelling and shrinking due to moisture, which leads to surface cracking and unevenness. This affects the overall flexural strength and increases the load on the keel ceiling. Summary of the Invention

[0005] For the purposes described above, the objective of this application is to modify diatomaceous earth-based mineral boards to achieve better moisture resistance, reduce swelling and shrinkage after moisture absorption, and improve overall strength.

[0006] First, this application provides a diatomaceous inorganic mineral board, grade A1, comprising a main body layer formed by lamination and an mounting layer disposed on the other side of the main body layer. The main body layer comprises the following components according to the mass ratio: 10 parts of inorganic fiber 0.5-1 part sepiolite fiber 15-20 parts of sulfoaluminate cement; 20-30 parts diatomaceous earth 0.5–1 part of tetraneedle-shaped zinc oxide whiskers Flame retardant 0.1 to 2 parts; Water-reducing agent: 0.5 to 1 part.

[0007] The aforementioned system, based on inorganic fibers, cement, and diatomaceous earth, has undergone minor adjustments. Firstly, a certain amount of sepiolite fiber has been added. Building upon the composite network system formed by the inorganic fibers, the small amount of sepiolite fiber utilizes its winding properties and toughness, while its interpenetrating structure reduces the swelling and shrinkage caused by moisture. Simultaneously, the sepiolite fiber itself provides good water retention, ensuring that the humidity regulation performance of the board is not significantly affected. Overall, the sepiolite fiber provides better toughness and a lower swelling rate in the system, reducing cracking caused by moisture. Furthermore, the tetraneedle-shaped zinc oxide whiskers act as a nucleating agent, serving as the central region of the sepiolite fiber network. Due to their higher surface reactivity, they reduce the adhesion of sepiolite fibers around the diatomaceous earth pores, improving the swelling and shrinkage performance and toughness of the system during preparation without affecting the overall humidity regulation and density. Based on the above, a certain amount of water-reducing agent is added, with a relatively large amount added, to compensate for the loss of system fluidity caused by sepiolite fibers. Simultaneously, sulfoaluminate cement is selected in the above system, which has better high-temperature strength properties and, compared to ordinary silicate cement, provides better early strength performance and better bonding with sepiolite fibers. Furthermore, due to the lower alkalinity of sulfoaluminate cement, it will not damage the diatomaceous earth system, thus providing better overall moisture regulation and strength.

[0008] Overall, after the above adjustments, the system's processing performance can be basically maintained, while the system's toughness and wet expansion and shrinkage properties are significantly improved, and the impact on moisture absorption and density is relatively small.

[0009] Preferably, the inorganic fiber specifically comprises the following components in parts by weight: 5-9 parts hollow fiberglass Ceramic fiber allowance.

[0010] The above system employs a composite system of hollow glass fiber and ceramic fiber. The hollow glass fiber provides an overall lightweight effect and an extruded tensile skeleton, while the ceramic fiber offers better tensile strength and support performance, as well as improved flame retardancy. It maintains a good skeleton even under combustion, and with the assistance of flame retardants, the system achieves an A1 flame retardancy rating. Overall, this formulation offers better fire resistance, better mechanical strength, lower density, and a relatively low overall price.

[0011] Preferably, the average length of the hollow glass fiber is 10-20 mm, and the average length of the ceramic fiber is 0.2-0.5 times that of the hollow glass fiber; And / or, The hollow glass fiber and ceramic fiber have an average diameter of 3 to 5 μm.

[0012] In the aforementioned system, a combination of long glass fibers and short ceramic fibers is employed. The short fibers are dispersed throughout the matrix. When microcracks initiate, the fibers dissipate energy through "pull-out work," preventing the cracks from propagating into macroscopic fractures. The long fibers bridge larger cracks, transferring stress through "bridging" to prevent the sheet from breaking. Simultaneously, during the formation of the skeleton, the long glass fibers better utilize their mechanical connectivity, while the short ceramic fibers act as fillers and supports, resulting in improved overall mechanical properties.

[0013] Preferably, the average length of the sepiolite fiber is 0.1 to 0.3 times the length of the hollow glass fiber.

[0014] In the above system, sepiolite short fibers were selected. Although sepiolite short fibers have a more significant impact on the processing performance of the system, resulting in a longer curing time, the overall flowability is still acceptable under the aforementioned high water-reducing agent content. Moreover, short fibers can better play a mechanical filling role in the system surrounding the long glass fibers, and can better form a cooperative system with tetragonal zinc oxide whiskers. Overall, compared with long sepiolite fibers, short fibers have better adhesion, provide better flowability, and the overall network system can fill the system more uniformly, thus improving the uniformity and strength of the system.

[0015] Preferably, the mass of the installation layer is 5-10% of the mass of the main layer, and the installation layer comprises rock wool felt, silicate cement and light calcium carbonate, wherein the mass of the silicate cement is 0.3-0.6 times that of the rock wool felt, and the mass of the light calcium carbonate is 0.15-0.3 times that of the rock wool felt.

[0016] In the above system, the installation layer is set on one side of the main layer. It uses rock wool system as the skeleton and silicate cement and light calcium carbonate as the base gel system. On the one hand, it provides a better fire-resistant system on the installation side and provides better flame retardant performance overall. On the other hand, it can also reduce the overall density. The light calcium carbonate is used to form a high-strength and lightweight gel system, which provides better installation strength and fire resistance on the installation side overall.

[0017] Preferably, a transition layer is provided between the main body layer and the surface paint layer, the transition layer comprising at least hollow glass microspheres and silicate cement, and the mass of the transition layer being 5 to 10% of the mass of the main body layer.

[0018] In the above scheme and system, the transition layer can cover part of the surface of the main layer. On the one hand, it improves the flatness and provides better surface adsorption performance, so that the paint layer can be better coated on the surface of the board. On the other hand, it can also provide a certain thickness and reduce the density of the system. At the same time, the transition layer can also better prevent the penetration of water vapor and provide better moisture resistance on the surface.

[0019] Preferably, the transition layer comprises the following components by weight: 10 parts of silicate cement; 1-2 parts of attapulgite; 5-10 parts of hollow glass microspheres; 0.05 to 0.1 parts of silane coupling agent.

[0020] In the aforementioned system, a certain amount of silane coupling agent is added to the transition layer, which ensures the strength of the system and provides better adhesion to the paint layer. Simultaneously, a small amount of attapulgite is added to the system. Attapulgite provides better flame retardant properties on the surface and, compared to other flame retardant additives, exhibits better compatibility in inorganic systems, is less prone to dripping, and shows even better compatibility in the aforementioned purely inorganic environment. It also provides certain reaction sites on the surface, allowing for better adhesion to the paint layer after combining with the silane coupling agent, and simultaneously forming physical cross-linking points, significantly improving the fire resistance rating. Furthermore, the pore structure of the attapulgite can complement the pores of diatomaceous earth, thus significantly improving overall dimensional stability, shrinkage resistance, moisture regulation, and strength.

[0021] Preferably, the preparation method of the above-mentioned diatom inorganic mineral plate includes the following steps: S1. Raw materials for laying the installation layer in the mold; S2. Inorganic fibers, sepiolite fibers, diatomaceous earth, and tetraneedle-shaped zinc oxide whiskers are broken down and mixed, and then a fiber web structure is formed by papermaking and laid in a mold. S3. After mixing the early-strength sulfoaluminate cement, ammonium polyphosphate, and water-reducing agent evenly in water, adjust the water volume to a flowability of 200-260 mm, then mix evenly and pour into the mold above, allowing it to penetrate into the fiber network structure and flow level, and initially flatten to the target thickness. S4. Initial static curing for 0.5–2 hours; S5. Add water to the transition layer to adjust the fluidity to 120-160mm. After mixing evenly, lay it on the surface of the layer structure obtained in step S4, then let it stand to cure and dry it at an environment not higher than 70℃.

[0022] In the above system, an installation layer is first laid, followed by the stacking of inorganic fibers, sepiolite fibers, diatomaceous earth, and tetraneedle-shaped zinc oxide whiskers in a papermaking manner to form a layered fiber structure. Then, the mixed cement slurry is poured onto the above system. Overall, during the mixing process, fiber breakage due to stirring is reduced, and it also helps to initially build the overall fiber skeleton and maximize the filling effect of shorter fibers in the system. Overall, this step requires higher fluidity to ensure smooth penetration of the cement slurry. A higher water content and a higher amount of water-reducing agent are used. With the presence of diatomaceous earth and sepiolite fibers, both have stronger water absorption properties, so there is no bleeding phenomenon.

[0023] Subsequently, after initial curing, a transition layer is added to the surface of the above system. In this process, the transition layer and the main layer have better bonding performance. Because the fiber web formed in this process has more fiber protrusions, the fibers will extend from the surface of the main layer and into the transition layer, thus forming better bonding performance between the two layers. Then the transition layer is cured on the surface. After curing, it can be sanded or directly coated with a paint layer, but it needs to be dried first to remove the water adsorbed in the diatomaceous earth and other components.

[0024] In addition, this application also relates to ceilings made from diatomaceous inorganic A1 grade mineral boards, which have low overall density, high strength, and good moisture resistance, and are not prone to cracking due to expansion and contraction in humid environments.

[0025] In addition, this application also relates to the installation method of the above-mentioned fireproof ceiling, including the following steps: leveling and fixing the keel, cutting the mineral board, then fixing the mineral board to the keel with self-tapping screws, then cutting a small amount of mineral board strips and bonding them to the joint area of ​​the two boards, then reinforcing with nails along the length of the strips, and then smoothing the joint with putty.

[0026] In summary, this application provides a diatomaceous earth inorganic A1 grade mineral board, which is based on diatomaceous earth as the main body and sulfoaluminate cement as the colloidal main body. It forms a cross-linked network structure through sepiolite fibers and tetraneedle-shaped zinc oxide whiskers. While not affecting the moisture regulation performance of the system, it also ensures the good moisture resistance of the system, improves the overall toughness, and reduces the expansion and contraction due to moisture. This makes it a good material for ceilings or other home decoration, providing good performance and a long quality guarantee. Detailed Implementation

[0027] The technical solutions in this application will be further described through the following specific embodiments.

[0028] For the following embodiments, the relevant performance was determined using the following experimental methods: 1. Non-combustible test: The flammability rating of the sample was determined in accordance with GB 8624-2012 "Test Method for Non-combustibility of Building Materials".

[0029] 2. Humidity regulation performance: Referring to JC / T 2082-2011 "Indoor building decoration materials with humidity regulation function", the 24-hour moisture absorption and the 24-hour moisture release of the system were measured in an environment of 75% relative humidity.

[0030] 3. Mechanical properties: Refer to Section 4.22 of GBT17657-2013 "Test Methods for Physical and Chemical Properties of Wood-based Panels and Decorative Wood-based Panels" to determine the impact toughness of the board, and refer to Section 4.26 to determine the compressive strength along the grain.

[0031] 4. Density: The density of the board shall be determined in accordance with GB / T 17657-2013 "Test Methods for Physical and Chemical Properties of Wood-based Panels and Decorative Wood-based Panels".

[0032] 5. Dimensional stability: Refer to Method 1 in Section 4.34 of GBT17657-2013 "Test Methods for Physical and Chemical Properties of Wood-based Panels and Decorative Wood-based Panels" to determine the thickness change rate under high humidity.

[0033] 6. Hanging performance test: Refer to the method in Section 4.21 of GBT17657-2013 "Test Methods for Physical and Chemical Properties of Wood-based Panels and Decorative Wood-based Panels" to determine the screw holding force.

[0034] Example 1: This example provides a diatomaceous earth inorganic A1 grade mineral board and a usable ceiling structure. Overall, it includes an installation layer, a main layer laid on the installation layer, a transition layer disposed on the main layer, and a paint layer coated on the transition layer. Specifically, it is prepared through the following steps: S1. The raw material for the mounting layer is laid at the bottom of the mold. Specifically, the quality control of the mounting layer is 10% of that of the main layer, and it specifically includes the following components: Rock wool felt (nominal density 60kg / m³) 3 (A1 fire retardant, asbestos-free) 10 copies Light calcium carbonate (bulk density 0.55 g / cm³) 3 5 copies 2 parts of silicate cement (ordinary silicate cement 42.5) The above components are dry-mixed and then directly laid on the bottom of the mold, and the overall shape is flattened by vibration.

[0035] S2. The inorganic fibers, diatomaceous earth, sepiolite fibers, and tetraneedle-shaped zinc oxide whiskers are roasted using a papermaking process to form a preliminary fiber network structure, specifically using the following configuration: First, slowly add the inorganic fibers to the water and stir for 10 minutes until they are evenly dispersed. During this process, add diatomaceous earth, sepiolite fibers, and tetragonal zinc oxide whiskers in three portions. Depending on the situation, a surfactant of no more than 1% of the total fiber mass can be added to improve dispersibility. If the dispersion is good, the surfactant may not need to be added. Then, use an 80-mesh stainless steel mesh as the filter layer and place a frame mold. Pour the fiber layer into the frame mold, then vibrate the frame mold and use negative pressure to filter out 80% of the water. The overall thickness of the fiber layer is controlled at 12±1 mm. The fiber layer is then transferred to the mold in step S1.

[0036] The inorganic fibers, per 10 parts by weight, specifically contain the following components: Hollow alkali-free glass fiber (average length 15mm, average diameter 3μm) 8 parts; Two parts of ceramic fiber (average length 3mm, average diameter 5μm).

[0037] The amounts of other components added per 10 parts by weight of inorganic fiber are as follows: Sepiolite fiber (aggregate fiber length 2mm, specific surface area 865m²) 2 / g) 1 serving; 20 parts of diatomaceous earth (porosity 85%, particle size 500 mesh, calcined); One part of four needle-like zinc oxide whiskers (average diameter of the central body is 1.0 μm, and the average length of the needles is 40 μm).

[0038] S3. Based on the above, sulfoaluminate cement, water-reducing agent, flame retardant and water are added to prepare cement slurry. The fluidity is controlled at 20℃ to be 240mm. The slurry is poured evenly into the mold. Then the mold is placed on a vibrating table with a frequency of 50Hz, an amplitude of 0.3mm and vibrating for 120 seconds. After the overall flow is leveled, a screw press is used to press it to a thickness of 8mm with a pressure of 1.0mPa and hold the pressure for 10min.

[0039] In the above system, the addition amounts of the remaining components, calculated per 10 parts of inorganic fiber, are as follows: Sulfoaluminate cement (low-alkalinity sulfoaluminate cement 42.5) 20 parts; 1 part of water-reducing agent (Kelone R-209 high-efficiency polycarboxylate water-reducing agent); Flame retardant (aluminum hydroxide powder), 1 part.

[0040] S4. Initially cure at 20℃ and 90% humidity for 1 hour to obtain the main layer; S5. Prepare the slurry for the transition layer, which includes silicate cement, attapulgite, hollow glass microspheres and silane coupling agent. The total mass of the materials is 10% of the mass of the materials in the main layer. Mix the above materials with water and adjust the fluidity to 135±5mm. Slowly apply the mixture to the surface of the main layer, smooth it with a scraper, and continue to let it stand for curing. Initially cure at 20℃ and 90% humidity for 60 hours, and then dry it at 70℃ for 5 hours.

[0041] Specifically, in the transition layer, the specific mass distribution is as follows: 10 parts of silicate cement (ordinary silicate cement 42.5); Attapulgite (200 mesh, 85% purity) 2 parts; Hollow glass microspheres (alkali-free glass microspheres, 30 mesh) 10 parts; 0.1 parts of silane coupling agent (KH-570).

[0042] The aforementioned mineral plaques can be used as ceiling panels, and they can be installed using the following methods: Level and fix the keel, cut the mineral board, and then fix the mineral board to the keel with self-tapping screws. Then cut a small amount of mineral board strips and glue them to the joint area of ​​the two boards. Then reinforce with nails along the length of the strips. Finally, smooth the joint with putty.

[0043] Example 2, based on Example 1, adjusts the material ratio in the main layer, specifically as follows, per 10 parts by weight of inorganic fiber: 0.5 parts sepiolite fiber; 30 parts diatomaceous earth; 0.5 parts of four needle-like zinc oxide whiskers; 1 part flame retardant; 0.5 parts water-reducing agent.

[0044] Example 3 is based on Example 1, with adjustments made to the hollow glass fiber and ceramic fiber. Specifically, every 10 parts by weight of inorganic fiber contains 9 parts hollow glass fiber and 1 part ceramic fiber.

[0045] Example 4: Based on Example 1, the hollow glass fiber and ceramic fiber are adjusted. Specifically, every 10 parts by weight of inorganic fiber includes 5 parts hollow glass fiber and 5 parts ceramic fiber.

[0046] Example 5: Based on Example 1, the hollow glass fiber and ceramic fiber are adjusted. Specifically, every 10 parts by weight of inorganic fiber includes 8 parts of hollow glass fiber and 2 parts of short hollow glass fiber, wherein the average length of the short hollow glass fiber is 4 mm and the average diameter is 4 μm.

[0047] Example 6, based on Example 1, uses different parameters for the control fiberglass, ceramic fiber, and sepiolite fiber. Specifically, Hollow alkali-free glass fiber: average length 20mm, average diameter 5μm; Ceramic fiber: average length 10mm, average diameter 5μm; Sepiolite fiber: aggregate fiber length 5mm, specific surface area 824m³ 2 / g.

[0048] Example 7, based on Example 1, uses different parameters for the control fiberglass, ceramic fiber, and sepiolite fiber. Specifically, Hollow alkali-free glass fiber: average length 10mm, average diameter 3μm; Ceramic fiber: average length 10mm, average diameter 5μm; Sepiolite fiber: aggregate fiber length 2mm, specific surface area 865m² 2 / g.

[0049] Example 8, based on Example 1, uses different parameters for the control fiberglass, ceramic fiber, and sepiolite fiber. Specifically, Hollow alkali-free glass fiber: average length 5mm, average diameter 3μm; Ceramic fiber: average length 5mm, average diameter 5μm; Sepiolite fiber: aggregate fiber length 2mm, specific surface area 865m² 2 / g.

[0050] Example 9, based on Example 1, uses different parameters for the control fiberglass, ceramic fiber, and sepiolite fiber. Specifically, Hollow alkali-free glass fiber: average length 20mm, average diameter 5μm; Ceramic fiber: average length 2mm, average diameter 3μm; Sepiolite fiber: aggregate fiber length 2mm, specific surface area 865m² 2 / g.

[0051] Example 10, based on Example 1, uses different parameters for the control fiberglass, ceramic fiber, and sepiolite fiber. Specifically, Hollow alkali-free glass fiber: average length 20mm, average diameter 5μm; Ceramic fiber: average length 8mm, average diameter 5μm; Sepiolite fiber: aggregate fiber length 6mm, specific surface area 811m² 2 / g.

[0052] Example 11, based on Example 1, uses different parameters for the control fiberglass, ceramic fiber, and sepiolite fiber. Specifically, Hollow alkali-free glass fiber: average length 10mm, average diameter 3μm; Ceramic fiber: average length 3mm, average diameter 5μm; Sepiolite fiber: aggregate fiber length 6mm, specific surface area 811m² 2 / g.

[0053] Example 12 differs from Example 1 in that no transition layer is added, and in step S4, the product is directly cured for 60 hours, followed by drying at 70°C for 5 hours.

[0054] It should be noted that in order to meet the thickness requirements of the actual process, the overall thickness can be slightly increased in this embodiment. For example, in this embodiment, the thickness is pressed to 8.5mm in step S3.

[0055] Example 13 differs from Example 1 in that, in step S4, the initial static curing time is 2 hours.

[0056] Example 14 differs from Example 1 in that, in step S4, the initial static curing time is 4 hours.

[0057] Example 15 differs from Example 1 in that the material ratio of the transition layer is adjusted. Specifically, the mass distribution of the material in the transition layer is as follows: 10 parts of silicate cement (ordinary silicate cement 42.5); Attapulgite (200 mesh, 85% purity) 1 part; Hollow glass microspheres (alkali-free glass microspheres, 30 mesh) 5 parts; 0.05 parts of silane coupling agent (KH-570).

[0058] Example 16 differs from Example 1 in that the material ratio of the transition layer is adjusted. Specifically, the mass distribution of materials in the transition layer is as follows: 10 parts of silicate cement (ordinary silicate cement 42.5); Hollow glass microspheres (alkali-free glass microspheres, 30 mesh) 12 parts; 0.1 parts of silane coupling agent (KH-570).

[0059] Example 17 differs from Example 1 in that the proportion of the transition layer is increased. Specifically, the quality of the transition layer is controlled to be 10% of the quality of the main layer.

[0060] Example 18 differs from Example 1 in that the proportion of the transition layer is increased. Specifically, the quality of the transition layer is controlled to be 15% of the quality of the main layer.

[0061] Example 19 differs from Example 1 in that, in steps S2 and S3, the papermaking process is not performed first. Instead, all materials are directly mixed and stirred evenly in a mixer, with the flowability controlled at 240 mm. The mixture is then poured into a mold and pressed to the target thickness. Example 20 differs from Example 19 in that the flowability is adjusted to 160 mm.

[0062] Meanwhile, the following comparative examples are set up for comparison with the embodiments.

[0063] In contrast to Example 1, in this comparative example, sepiolite fibers were replaced with ceramic fibers of equal mass, based on Example 1.

[0064] In Comparative Example 2, based on Example 1, sepiolite fibers were replaced with hollow glass fibers of equal mass.

[0065] In Comparative Example 3, based on Example 1, sulfoaluminate cement was replaced by ordinary silicate cement 42.5 by an equal mass.

[0066] Comparative Example 4: In this comparative example, tetra-needle zinc oxide whiskers were not added, based on Example 1.

[0067] Experiments were conducted on Examples 1-20 and Control Examples 1-4, and the results are shown in the table below.

[0068] By comparing Examples 1 and 2 with the comparative examples, it can be seen that in the system, compared with Examples 1 and 2, in Comparative Examples 1 and 2, due to the absence of sepiolite fibers, the individual tetragonal zinc oxide whiskers cannot form a network structure. Therefore, the overall mechanical strength is still reduced and the thickness change rate is increased. In Comparative Example 3, silicate cement was used instead of sulfoaluminate cement, which has insufficient early strength. As a result, the fibers are prone to settling during the curing process, and the density is increased to some extent. The impact toughness and compressive strength parallel to the grain are reduced to some extent. In Comparative Example 4, the absence of tetragonal zinc oxide whiskers makes it easier for sepiolite fibers to adhere to the periphery of diatomaceous earth. In addition to reducing the overall moisture regulation performance, it also leads to an increase in overall density and thickness change rate, and a slight decrease in mechanical properties.

[0069] In Examples 3-5, the inorganic fibers were adjusted. In Example 5, no ceramic fibers were added, which not only reduced the impact toughness but also affected the flame retardant properties. In Examples 6-11, the lengths of the fibers were adjusted. In Example 7, both the hollow glass fiber and the ceramic fiber were long fibers, making it easier for fine cracks to form in small areas and resulting in poor filling performance. In Example 8, both the glass fiber and the ceramic fiber were short fibers, resulting in relatively poor tensile strength. Overall, Examples 7 and 8 showed some degree of mechanical property loss. In Example 9, the ceramic fibers were too short, which made them more prone to agglomeration and reduced dispersibility, leading to lower compressive strength. It also affected the heat resistance, as they could not form a good ceramic skeleton after heating and were prone to softening. In Example 10, the sepiolite fibers were too long, which negatively impacted the overall mechanical properties and also led to some loss in the system's humidity regulation and moisture expansion / shrinkage properties.

[0070] In Example 12, the absence of a transition layer not only potentially reduces the adhesion of the surface paint layer but also negatively impacts the system's moisture absorption properties. Furthermore, while maintaining the overall thickness, the transition layer reduces the system's density to some extent. In Example 14, the excessively long initial curing time weakens the bond between the transition layer and the main layer, leading to a decrease in the system's mechanical strength and increased susceptibility to swelling and shrinkage in the gaps. In Example 16, the lack of attapulgite also resulted in more pronounced swelling and shrinkage. Subsequent observations revealed that Example 16 was more prone to surface cracking and exhibited poor paint adhesion, demonstrating the crucial role of attapulgite in this system.

[0071] In Examples 19 and 20, the fibers were directly mixed with other components into a slurry before casting. This approach can lead to damage to the fibers during the mixing process. Furthermore, at lower fluidity (i.e., Example 20), the overall uniformity is poor, the diatomaceous earth cannot fully utilize its moisture-regulating properties, and it is more prone to agglomeration. At higher fluidity (i.e., Example 19), the overall strength will be somewhat reduced.

[0072] This specific embodiment is merely an explanation of this application and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of the claims of this application.

Claims

1. A diatomaceous inorganic Al-class mineral board, characterized by, The main body layer is formed by laminating and comprises the following components by mass ratio: Inorganic fiber 10 parts Seppiolite fiber 0.5-1 part Sulfoaluminate cement 15-20 parts Diatomite 20-30 parts Four acicular zinc oxide whiskers 0.5-1 part Flame retardant 0.1-2 parts Water reducing agent 0.5-1 part.

2. A diatomaceous inorganic Al-class mineral plate according to claim 1, characterized in that, The inorganic fiber specifically comprises the following components by mass: Hollow glass fiber 5-9 parts Ceramic fiber the rest.

3. A diatomaceous inorganic Al-class mineral plate according to claim 2, characterized in that, The average length of the hollow glass fiber is 10-20 mm, and the average length of the ceramic fiber is 0.2-0.5 times that of the hollow glass fiber. And / or, The average diameter of the hollow glass fiber and the ceramic fiber is 3-5 μm.

4. A diatomaceous inorganic Al-class mineral plate according to claim 3, characterized in that, The average length of the seppiolite fiber is 0.1-0.3 times that of the hollow glass fiber.

5. A diatomaceous inorganic Al-class mineral plate according to claim 1, characterized in that, The mass of the mounting layer is 5-10% of the mass of the main body layer, and the mounting layer comprises rock wool felt, silicate cement, and light calcium carbonate, wherein the mass of the silicate cement is 0.3-0.6 times that of the rock wool felt, and the mass of the light calcium carbonate is 0.15-0.3 times that of the mass of the rock wool felt.

6. A diatomaceous inorganic Al-class mineral plate according to claim 1, characterized in that, A transition layer is arranged between the main body layer and the surface paint layer, and the transition layer at least comprises hollow glass beads and silicate cement, and the mass of the transition layer is 5-10% of the mass of the main body layer.

7. A diatomaceous inorganic Al-class mineral plate according to claim 6, characterized in that, The transition layer comprises the following components by mass: Silicate cement 10 parts Attapulgite 1-2 parts Hollow glass beads 5-10 parts Silane coupling agent 0.05-0.1 parts.

8. A diatomaceous inorganic Al-class mineral plate according to claim 6, characterized in that, The preparation method comprises the following steps: S1, laying the raw materials of the mounting layer in a mold; S2, mixing the inorganic fiber, seppiolite fiber, diatomite, and four acicular zinc oxide whiskers, then forming a fiber web structure in a papermaking manner, and laying in the mold; S3, uniformly mixing the early-strength sulfoaluminate cement, the ammonium polyphosphate, and the water reducing agent in water, adjusting the water amount to a flow degree of 200-260 mm, then uniformly mixing and pouring into the mold, so that the mixture penetrates into the fiber web structure and flows flat, and the initial thickness is flattened to the target thickness; S4, initial standing and curing for 0.5-2 h; S5, adjusting the flow degree of the transition layer to 120-160 mm by adding water, uniformly mixing, then laying on the surface of the layer structure obtained in step S4, then standing and curing, and drying in an environment not higher than 70°C.

9. A fire resistant ceiling, characterised in that, A diatom inorganic A1-grade mineral plate comprising any one of claims 1-8.

10. The method of installing a fire-rated suspended ceiling of claim 9, wherein, The method comprises the following steps: leveling the keel, cutting the mineral plate, then fixing the mineral plate on the keel by self-tapping screws, then cutting a small amount of plate strips from the mineral plate and bonding them in the joint area of the two plates, then reinforcing along the length direction of the plate strips by nailing, and then scraping the joint with putty.

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