Fireproof, moistureproof, wear-resistant and corrosion-resistant inorganic sheet and preparation method thereof

Abstract

The invention relates to the technical field of inorganic composite materials, in particular to a fireproof, moistureproof, wear-resistant and corrosion-resistant inorganic sheet and a preparation method thereof. The sheet comprises a cementing material composite system, a complexing agent, a graded aggregate system, a hybrid fiber reinforced network, a chemical additive and water, and during preparation, vacuum roll forming and high-temperature and high-pressure steam curing processes are adopted to synergistically improve mechanical and durability. The sheet has excellent fireproof, moisture-proof, wear-resistant and corrosion-resistant performance, the overall performance is synergistically improved, and the sheet is suitable for building and decoration materials in severe environments.

Description

Technical Field

[0001] This invention relates to the field of inorganic composite materials technology, specifically to a fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet and its preparation method. Background Technology

[0002] Inorganic sheet materials, mainly composed of cement, gypsum, calcium silicate and other cementing materials, have advantages such as non-combustibility, durability and moderate cost, and are the core materials in the fields of building fire protection and partitions. However, in demanding environments such as underground engineering, coastal buildings, chemical workshops, food processing plants, and transportation hubs, traditional inorganic sheets often fail due to the following inherent defects: 1. Porous structure leading to poor moisture resistance: The porous structure formed by traditional processes easily absorbs moisture and corrosive media, causing internal steel reinforcement corrosion, freeze-thaw damage, and strength loss. Performance deteriorates rapidly in humid environments. 2. Insufficient toughness leading to brittle fracture: In pursuit of high strength, density is often increased at the expense of toughness, resulting in poor impact and flexural strength of the sheet, making it prone to brittle cracking during transportation, installation, and use. 3. Weak resistance to chemical corrosion: Sheets based on silicate cement have a high content of calcium hydroxide, a hydration product, which is prone to dissolution and expansion reactions (such as sulfate corrosion) in acidic or saline media, leading to loose structure and peeling. 4. Difficulty in maintaining surface wear resistance: It is difficult to balance surface hardness and overall toughness. Traditional surface hardening treatments (such as applying wear-resistant coatings) are prone to peeling off from the substrate, and the introduction of organic components affects fire resistance and durability.

[0003] Currently, to improve the aforementioned individual properties, methods such as adding water-repellent agents, polymer emulsions, corrosion-resistant admixtures, or surface impregnation treatments are commonly used. However, these methods are mostly "performance additives," which can easily create new contradictions, such as toughening agents introducing flammability, water-repellent agents reducing bond strength, and the processes are complex and costly. Therefore, there is an urgent need to develop a new type of inorganic sheet material that integrates high density, high toughness, intrinsic water repellency, and high corrosion resistance, and is simple to process, starting from the material composition and microstructure design.

[0004] Chinese Patent Publication No. CN119058203B discloses a lightweight green fire-resistant decorative panel and its preparation method. Specifically, it discloses a lightweight green fire-resistant decorative panel and its preparation method. The lightweight green fire-resistant decorative panel uses polypropylene resin, polyvinyl chloride resin, caffeic acid-modified reed straw fiber, aluminum-titanium composite coupling agent JTW-1816, surface-modified shell powder, and diatomaceous earth mixed filler as main raw materials. A lightweight green substrate is prepared using soybean-based adhesive and MDI adhesive as binders. Ultra-thin fiberboard is used as the surface material, and vinyl chloride copolymer emulsion, soybean-based adhesive, and MDI adhesive are used as the finishing film material. Together, these materials prepare a lightweight green fire-resistant decorative panel with excellent performance. The lightweight green fire-resistant decorative panel obtained in this application has the advantages of being waterproof and moisture-proof, highly wear-resistant, having high bonding strength, good immersion and peel performance, resistance to cold and heat cycles, stain resistance, excellent flame retardant properties, and being safe and environmentally friendly. However, the panel produced by this invention only has the characteristics of being waterproof, moisture-proof, and highly wear-resistant, but does not have anti-corrosion properties. Summary of the Invention

[0005] The purpose of this invention is to provide a fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet and its preparation method, so as to solve the problems of poor moisture resistance, insufficient toughness, weak chemical corrosion resistance, and poor surface wear resistance of traditional sheets mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet material comprises the following components in parts by weight: 45-60 parts of a cementitious composite system, 4-7 parts of a composite agent, 30-38 parts of a graded aggregate system, 2.0-4.0 parts of a mixed fiber reinforced network, 0.4-0.8 parts of a chemical admixture, and water; The cementitious composite system consists of sulfoaluminate cement, metakaolin, and silica fume, with a mass ratio of (5.5~6.5):(2.5~3.5):1. The composite agent is prepared by premixing nano-silica with silane coupling agent surface modification, calcium stearate and lithium slag powder in a mass ratio of (0.8~1.2):1:(3.5~4.5); The graded aggregate system is composed of 40-70 mesh quartz sand, 70-140 mesh quartz sand and 200-400 mesh quartz powder in a mass ratio of 1:(1.4-1.6):(0.6-0.8); The hybrid fiber reinforced network is composed of polypropylene fibers with a length of 8-12 mm and basalt fibers with a length of 10-15 mm, with a mass ratio of (1.5-2.5):1. The water usage is such that the ratio of water to the total mass of the cementitious material composite system is 0.23 to 0.26.

[0007] As a preferred embodiment, in a fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet, the silane coupling agent is γ-aminopropyltriethoxysilane; Preferably, in a fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet, the chemical additive is a polycarboxylate superplasticizer; As a preferred embodiment, in a fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet, the mass ratio of sulfoaluminate cement, metakaolin, and silica fume in the cementitious composite system is 6:3:1.

[0008] As a preferred embodiment, in a fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet, the mass ratio of the silane coupling agent-modified nano-silica, calcium stearate, and lithium slag powder in the composite agent is 1:1:4.

[0009] As a preferred embodiment, in a fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet, the mass ratio of polypropylene fiber to basalt fiber in the hybrid fiber reinforced network is 2:1.

[0010] This invention is based on the theory of closest packing and the principles of ultra-high performance cement-based materials. It achieves physical packing densification through gradient particle size matching of sulfoaluminate cement, metakaolin, and silica fume, and three-level gradation of aggregates. At the same time, it utilizes nano-surface chemical modification technology to anchor nano-silica grafted with silane coupling agent and calcium stearate on the surface of lithium slag powder, constructing a composite micro-aggregate with hydrophobic function. While filling nanopores, it imparts hydrophobicity to the material itself. Furthermore, it ensures the uniformity and low porosity of the slurry through a low water-binder ratio and polycarboxylate superplasticizer, and introduces polypropylene fiber and basalt fiber to form a multi-level toughening network. Finally, it forms a multi-scale composite structure of nano-hydrophobicity, micron-filling, and millimeter-toughening at the microscopic level, thereby synergistically achieving a breakthrough in comprehensive performance of fire resistance, moisture resistance, wear resistance, and corrosion resistance.

[0011] A method for preparing a fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet includes the following steps: Step S1: Place 100-125 parts by weight of nano-silica with a particle size of 15-30 nm and 3-5 parts by weight of γ-aminopropyltriethoxysilane in a high-speed mixer and stir at 80-90°C at a speed of 1000-2000 rpm for 20-30 minutes to allow the silane coupling agent to be fully hydrolyzed and grafted onto the surface of the nano-silica. The modified nano-silica, 125 parts by weight of calcium stearate, and 500 parts by weight of dried lithium slag powder have a specific surface area ≥400 m². 2 / kg are added together into the three-dimensional motion mixer and mixed at a speed of 30~40rpm for 45~60 minutes until the material is uniformly gray. The resulting compound should be sealed and stored in a moisture-proof container. Step S2: According to the proportions of claim 1, the cementitious composite system consisting of sulfoaluminate cement, metakaolin, and silica fume, along with the graded quartz sand and powder, are added together with the composite agent and polycarboxylate superplasticizer prepared in step S1 into a forced planetary mixer. Dry-mix at 50-70 rpm for 3-5 minutes to ensure uniform macroscopic distribution. Add 70%-75% of the total water volume, then increase the mixing speed to 100-140 rpm for 2-3 minutes to form a uniform, viscous plastic slurry. Under continuous mixing, add polypropylene fibers (8-12 mm in length) and basalt fibers (10-15 mm in length) at a mass ratio of 2:1, and slowly and evenly sprinkle them into the slurry. Continue mixing at medium speed for 3-5 minutes until the fibers are completely coated by the slurry and there are no visible fiber clumps. Add the remaining 25%-30% of the mixing water, and mix at 140-180 rpm. Stir at rpm for 1-2 minutes to form a high-density fiber-reinforced slurry with suitable fluidity and uniform fiber dispersion. Quickly inject the slurry into a mold pre-placed on a continuous vacuum roller press. Start the equipment and squeeze and degas the slurry under vacuum conditions through a pair of opposing rotating pressure rollers. Control the pressure between the rollers at 8-12 MPa to form a wet blank with uniform thickness and density. Step S3: Transfer the mold with the wet blank to a constant temperature and humidity curing chamber and cure it at a temperature of 45~55℃ and a relative humidity of ≥95% for 4~6 hours to allow the cementitious material to initially hydrate and obtain demolding strength. After pre-curing, carefully remove the mold to obtain a complete wet slab. Place the slab into an autoclave and heat it at a uniform rate to 180~190℃ within 1.5~2.5 hours, while simultaneously increasing the pressure to 1.2~1.4MPa. Cure it under constant temperature and pressure for 8~12 hours. Then, cool it down to below 60℃ and normal pressure within at least 2.5 hours to prevent the sheet from cracking due to excessive cooling, and obtain a semi-finished product. Step S4: Dry the semi-finished product obtained in step S3 at 60~80℃ to constant weight to remove internal free moisture and open capillary pore channels. Then, perform surface treatment with sodium silicate solution, remove the sheet, drain excess solution from the surface, and then naturally cure it for more than 72 hours at a temperature of 20~25℃ and a relative humidity of 50~70% to allow the penetrated sodium silicate to fully react with the matrix and generate calcium silicate gel, thus completing the deep sealing of internal pores and surface strengthening, and obtaining the finished product.

[0012] Preferably, in step S2, the vacuum degree during vacuum roll forming is not lower than -0.085 MPa.

[0013] Preferably, in step S4, the concentration of the sodium silicate aqueous solution is 0.5~2 mol / L, and the surface treatment method is immersion at room temperature and pressure for 20~30 minutes.

[0014] Compared with the prior art, the beneficial effects of the present invention are: 1. This solution integrates the surface modification of nano-silica, the hydrophobic groups of calcium stearate, and the micro-aggregate function of lithium slag powder by designing a composite agent. This composite agent is not a simple physical mixture, but achieves chemical anchoring of the hydrophobic function on the surface of the micro-aggregate through a silane coupling agent, so that it participates in the microstructure construction of the material as a functional component. This fundamentally changes the hydrophilic nature of traditional inorganic materials, enabling them to obtain stable and long-lasting bulk impermeability, achieving a qualitative change from prevention to non-absorption. This is a solution to the problem of performance degradation of inorganic sheets in humid environments.

[0015] 2. The ultra-low water-cement ratio is a prerequisite for achieving high density in this solution, but it relies on polycarboxylate superplasticizers to ensure workability and vacuum roll forming to remove unavoidable residual air bubbles in the low water-cement ratio slurry. Similarly, the activity potential of the cementitious material system and the network reinforcement potential of the fibers must be fully activated and cured through a specific process of high-temperature and high-pressure steam curing to generate a stable microstructure with high strength and low porosity. Each link is interdependent and mutually supportive, avoiding technical shortcomings, and enabling the seemingly contradictory high-performance requirements of fire resistance, moisture resistance, wear resistance, and corrosion resistance to be simultaneously achieved in a coordinated system. Detailed Implementation

[0016] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of the present application. Example 1

[0017] A fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet material comprises the following components in parts by weight: 50 parts of a cementitious composite system, 5 parts of a composite agent, 33 parts of a graded aggregate system, 3.0 parts of a mixed fiber reinforced network, 0.6 parts of a chemical additive, and water; The cementitious composite system consists of sulfoaluminate cement, metakaolin, and silica fume, with a mass ratio of 6:3:1. The composite agent is prepared by premixing nano-silica with γ-aminopropyltriethoxysilane surface modification, calcium stearate and lithium slag powder in a mass ratio of 1:1:4; The graded aggregate system consists of 50-mesh quartz sand, 90-mesh quartz sand and 300-mesh quartz powder in a mass ratio of 1:1.5:0.8; The hybrid fiber reinforced network consists of polypropylene fibers with a length of 10 mm and basalt fibers with a length of 12 mm, with a mass ratio of 2:1. The water usage meets the requirement that the ratio of the total mass of the water and cementitious material composite system is 0.24.

[0018] The chemical admixture is a polycarboxylate superplasticizer; A method for preparing a fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet includes the following steps: Step S1: 125 parts by weight of nano-silica with a particle size of 20 nm and 4 parts by weight of γ-aminopropyltriethoxysilane were placed in a high-speed mixer and stirred at 80°C and 1500 rpm for 25 minutes to allow the silane coupling agent to be fully hydrolyzed and grafted onto the surface of the nano-silica. The modified nano-silica, 125 parts by weight of calcium stearate, and 500 parts by weight of dried lithium slag powder had a specific surface area of ​​500 m². 2 / kg are added together into the three-dimensional motion mixer and mixed at 40 rpm for 45 minutes until the material is uniformly gray. The resulting compound should be sealed and stored in a moisture-proof container. Step S2: According to the above proportions, the cementitious composite system consisting of sulfoaluminate cement, metakaolin, and silica fume, along with the graded quartz sand and powder, are added to a forced planetary mixer along with the composite agent and polycarboxylate superplasticizer prepared in Step S1. The mixture is dry-mixed at 60 rpm for 4 minutes to ensure uniform macroscopic distribution. 70% of the total water is added, and the mixture is stirred at 120 rpm for 2 minutes to form a uniform, viscous plastic slurry. While continuously stirring, 10mm long polypropylene fibers and 12mm long basalt fibers (by mass ratio 2:1) are evenly and slowly sprinkled into the slurry. The mixture is then stirred at medium speed for 4 minutes until the fibers are completely coated with the slurry and there are no visible fiber clumps. The remaining 30% of the mixing water is added, and the mixture is stirred at 160 rpm for 2 minutes to form a high-density fiber-reinforced slurry with suitable fluidity and uniform fiber dispersion. The slurry is then quickly injected into a mold pre-placed on a continuous vacuum roller press. The equipment is started, and the mixture is stirred at a vacuum degree of -0.095. Under the condition of MPa, the slurry is squeezed and vented by a pair of opposing rotating pressure rollers, and the pressure between the rollers is controlled at 10MPa to form a wet blank with uniform thickness and density. Step S3: Transfer the mold with the wet blank to a constant temperature and humidity curing chamber and let it stand for 5 hours at a temperature of 50℃ and a relative humidity of 95% to allow the cementitious material to initially hydrate and obtain demolding strength. After the pre-curing is completed, carefully remove the mold to obtain a complete wet slab. Place the slab into an autoclave and heat it to 190℃ at a uniform rate within 2 hours, while simultaneously increasing the pressure to 1.4MPa. Then, cure it under constant temperature and pressure for 10 hours. Afterward, cool it down to 40℃ and normal pressure within 3 hours to prevent the sheet from cracking due to excessive cooling, and obtain a semi-finished product. Step S4: Dry the semi-finished product obtained in step S3 at 80°C to constant weight to remove internal free moisture and open capillary pore channels. Then, immerse it in a 1 mol / L sodium silicate solution at room temperature and pressure for 30 minutes. Remove the sheet, drain the excess solution from the surface, and then cure it naturally for 96 hours at 25°C and 60% relative humidity to allow the infiltrated sodium silicate to fully react with the matrix and generate calcium silicate gel, thus completing the deep sealing of internal pores and surface strengthening, and obtaining the finished product. Example 2

[0019] A fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet material comprises the following components in parts by weight: 45 parts of a cementitious composite system, 4 parts of a composite agent, 30 parts of a graded aggregate system, 2.0 parts of a mixed fiber reinforced network, 0.4 parts of a chemical additive, and water; The cementitious composite system consists of sulfoaluminate cement, metakaolin, and silica fume, with a mass ratio of 6:3:1. The composite agent is prepared by premixing nano-silica with γ-aminopropyltriethoxysilane surface modification, calcium stearate and lithium slag powder in a mass ratio of 1:1:4; The graded aggregate system consists of 50-mesh quartz sand, 90-mesh quartz sand and 300-mesh quartz powder in a mass ratio of 1:1.5:0.8; The hybrid fiber reinforced network consists of polypropylene fibers with a length of 10 mm and basalt fibers with a length of 12 mm, with a mass ratio of 2:1. The water usage should meet the requirement that the ratio of water to the total mass of the cementitious material composite system is 0.23.

[0020] The chemical admixture is a polycarboxylate superplasticizer; A method for preparing a fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet includes the following steps: Step S1: 100 parts by weight of nano-silica with a particle size of 20 nm and 4 parts by weight of γ-aminopropyltriethoxysilane were placed in a high-speed mixer and stirred at 80°C and 1500 rpm for 25 minutes to allow the silane coupling agent to be fully hydrolyzed and grafted onto the surface of the nano-silica. The modified nano-silica, 125 parts by weight of calcium stearate, and 500 parts by weight of dried lithium slag powder had a specific surface area of ​​500 m². 2 / kg are added together into the three-dimensional motion mixer and mixed at 40 rpm for 45 minutes until the material is uniformly gray. The resulting compound should be sealed and stored in a moisture-proof container. Step S2: According to the above proportions, the cementitious composite system consisting of sulfoaluminate cement, metakaolin, and silica fume, along with the graded quartz sand and powder, are added to a forced planetary mixer along with the composite agent and polycarboxylate superplasticizer prepared in Step S1. The mixture is dry-mixed at 60 rpm for 4 minutes to ensure uniform macroscopic distribution. 65% of the total water is added, and the mixture is stirred at 120 rpm for 2 minutes to form a uniform, viscous plastic slurry. While continuously stirring, 10mm long polypropylene fibers and 12mm long basalt fibers (by mass ratio 2:1) are evenly and slowly sprinkled into the slurry. The mixture is then stirred at medium speed for 4 minutes until the fibers are completely coated with the slurry and there are no visible fiber clumps. The remaining 35% of the mixing water is added, and the mixture is stirred at 160 rpm for 2 minutes to form a high-density fiber-reinforced slurry with suitable fluidity and uniform fiber dispersion. The slurry is then quickly injected into a mold pre-placed on a continuous vacuum roller press. The equipment is started, and the mixture is stirred at a vacuum degree of -0.095. Under the condition of MPa, the slurry is squeezed and vented by a pair of opposing rotating pressure rollers, and the pressure between the rollers is controlled at 10MPa to form a wet blank with uniform thickness and density. Step S3: Transfer the mold with the wet blank to a constant temperature and humidity curing chamber and let it stand for 5 hours at a temperature of 50℃ and a relative humidity of 95% to allow the cementitious material to initially hydrate and obtain demolding strength. After the pre-curing is completed, carefully remove the mold to obtain a complete wet slab. Place the slab into an autoclave and heat it to 190℃ at a uniform rate within 2 hours, while simultaneously increasing the pressure to 1.4MPa. Then, cure it under constant temperature and pressure for 10 hours. Afterward, cool it down to 40℃ and normal pressure within 3 hours to prevent the sheet from cracking due to excessive cooling, and obtain a semi-finished product. Step S4: Dry the semi-finished product obtained in step S3 at 80°C to constant weight to remove internal free moisture and open capillary pore channels. Then, immerse it in a 1 mol / L sodium silicate solution at room temperature and pressure for 30 minutes. Remove the sheet, drain the excess solution from the surface, and then cure it naturally for 96 hours at 25°C and 60% relative humidity to allow the infiltrated sodium silicate to fully react with the matrix and generate calcium silicate gel, thus completing the deep sealing of internal pores and surface strengthening, and obtaining the finished product. Example 3

[0021] A fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet material comprises the following components in parts by weight: 60 parts of a cementitious composite system, 7 parts of a composite agent, 38 parts of a graded aggregate system, 4.0 parts of a mixed fiber reinforced network, 0.8 parts of a chemical additive, and water; The cementitious composite system consists of sulfoaluminate cement, metakaolin, and silica fume, with a mass ratio of 6:3:1. The composite agent is prepared by premixing nano-silica with γ-aminopropyltriethoxysilane surface modification, calcium stearate and lithium slag powder in a mass ratio of 1:1:4; The graded aggregate system consists of 50-mesh quartz sand, 90-mesh quartz sand and 300-mesh quartz powder in a mass ratio of 1:1.5:0.8; The hybrid fiber reinforced network consists of polypropylene fibers with a length of 10 mm and basalt fibers with a length of 12 mm, with a mass ratio of 2:1. The water usage meets the requirement that the ratio of the total mass of the water and cementitious material composite system is 0.26.

[0022] The chemical admixture is a polycarboxylate superplasticizer; A method for preparing a fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet includes the following steps: Step S1: 125 parts by weight of nano-silica with a particle size of 20 nm and 4 parts by weight of γ-aminopropyltriethoxysilane were placed in a high-speed mixer and stirred at 80°C and 1500 rpm for 25 minutes to allow the silane coupling agent to be fully hydrolyzed and grafted onto the surface of the nano-silica. The modified nano-silica, 125 parts by weight of calcium stearate, and 500 parts by weight of dried lithium slag powder had a specific surface area of ​​500 m². 2 / kg are added together into the three-dimensional motion mixer and mixed at 40 rpm for 45 minutes until the material is uniformly gray. The resulting compound should be sealed and stored in a moisture-proof container. Step S2: According to the above proportions, the cementitious composite system consisting of sulfoaluminate cement, metakaolin, and silica fume, along with the graded quartz sand and powder, are added to a forced planetary mixer along with the composite agent and polycarboxylate superplasticizer prepared in Step S1. The mixture is dry-mixed at 60 rpm for 4 minutes to ensure uniform macroscopic distribution. 75% of the total water is added, and the mixture is stirred at 120 rpm for 2 minutes to form a uniform, viscous plastic slurry. While continuously stirring, 10mm long polypropylene fibers and 12mm long basalt fibers (by mass ratio 2:1) are evenly and slowly sprinkled into the slurry. The mixture is then stirred at medium speed for 4 minutes until the fibers are completely coated with the slurry and there are no visible fiber clumps. The remaining 25% of the mixing water is added, and the mixture is stirred at 160 rpm for 2 minutes to form a high-density fiber-reinforced slurry with suitable fluidity and uniform fiber dispersion. The slurry is then quickly injected into a mold pre-placed on a continuous vacuum roller press. The equipment is started, and the mixture is stirred at a vacuum degree of -0.095. Under the condition of MPa, the slurry is squeezed and vented by a pair of opposing rotating pressure rollers, and the pressure between the rollers is controlled at 10MPa to form a wet blank with uniform thickness and density. Step S3: Transfer the mold with the wet blank to a constant temperature and humidity curing chamber and let it stand for 5 hours at a temperature of 50℃ and a relative humidity of 95% to allow the cementitious material to initially hydrate and obtain demolding strength. After the pre-curing is completed, carefully remove the mold to obtain a complete wet slab. Place the slab into an autoclave and heat it to 190℃ at a uniform rate within 2 hours, while simultaneously increasing the pressure to 1.4MPa. Then, cure it under constant temperature and pressure for 10 hours. Afterward, cool it down to 40℃ and normal pressure within 3 hours to prevent the sheet from cracking due to excessive cooling, and obtain a semi-finished product. Step S4: Dry the semi-finished product obtained in step S3 at 80°C to constant weight to remove internal free moisture and open capillary pore channels. Then, immerse it in a 1 mol / L sodium silicate solution at room temperature and pressure for 30 minutes. Remove the sheet, drain the excess solution from the surface, and then cure it naturally for 96 hours at 25°C and 60% relative humidity to allow the infiltrated sodium silicate to fully react with the matrix and generate calcium silicate gel, thus completing the deep sealing of internal pores and surface strengthening, and obtaining the finished product.

[0023] Comparative Example 1 The only difference from Example 1 is that: 45 parts of the cementitious material composite system, 4 parts of the composite agent, 30 parts of the graded aggregate system, 2.0 parts of the mixed fiber reinforced network, 0.4 parts of the chemical admixture, and water are weighed out, wherein the ratio of water to the total mass of the cementitious material composite system is 0.20, for later use; Comparative Example 2 The only difference from Example 1 is that: 60 parts of the cementitious material composite system, 7 parts of the composite agent, 38 parts of the graded aggregate system, 4.0 parts of the mixed fiber reinforced network, 0.8 parts of the chemical admixture, and water are weighed out, wherein the ratio of water to the total mass of the cementitious material composite system is 0.28, for later use; Comparative Example 3 The only difference from Example 1 is that there is no composite agent, and the same amount of ordinary quartz powder is used instead.

[0024] Comparative Example 4 The only difference from Example 1 is that an equal amount of ordinary silicate cement is used to completely replace sulfoaluminate cement, metakaolin, and silica fume system.

[0025] Comparative Example 5 The only difference from Example 1 is that only equal parts by weight of polypropylene fiber are used, and basalt fiber is not included.

[0026] Comparative Example 6 The only difference from Example 1 is that 60-mesh quartz sand is used to replace all aggregates by the same mass.

[0027] Comparative Example 7 The only difference from Example 1 is that in step S3, the high-temperature and high-pressure steam curing is cancelled and replaced with standard conditions: 20°C, RH>95%, curing for 28 days.

[0028] Comparative Example 8 The only difference from Example 1 is that the sodium silicate solution impregnation treatment is omitted in step S4.

[0029] Comparative Example 9 The only difference from Example 1 is that in step S4, there is no drying and direct impregnation.

[0030] Performance testing: 28d flexural strength: Refer to GB / T 17671-2021 "Test Method for Strength of Cement Mortar" to evaluate the ultimate bearing capacity of the material under three-point bending load, which directly reflects its mechanical toughness; Abrasion resistance: Refer to GB / T 3810.6-2016 "Test methods for ceramic tiles - Part 6: Determination of abrasion depth of unglazed tiles", use an abrasion testing machine, fix the sample on a rotating disk, apply a specific load to the grinding steel wheel above it, and the sample rubs against the steel wheel under the drive of the rotating disk. After a specified number of rotations, accurately weigh the mass loss of the sample.

[0031] 48h water absorption rate: Referencing GB / T 3810.3-2016 "Test Methods for Ceramic Tiles Part 3: Determination of Water Absorption, Apparent Porosity, Apparent Relative Density and Bulk Density", this measure measures the open porosity of the material and its ability to resist moisture intrusion, and is a direct indicator for evaluating "moisture-proof" performance.

[0032] Acid resistance (mass loss rate): The sample, dried to constant weight and with a mass of M1, is completely immersed in a 5% sulfuric acid solution at room temperature and sealed for 30 days. During this period, the solution is changed regularly to maintain the acid concentration. After removal, the sample is thoroughly rinsed with clean water and dried again to constant weight. The mass M2 after corrosion is then measured. The mass loss rate (%) is calculated using the formula (M1-M2) / M1×100%. The key to this test lies in the accurate preparation of the acid concentration, the airtightness of the immersion process, and the thorough removal of any adhering substances from the corroded surface.

[0033] Fire resistance rating: Referencing GB 8624-2012 "Classification of Combustion Performance of Building Materials and Products", samples of specified dimensions were placed in a tube furnace at 750℃, and their temperature rise, mass loss and continuous burning time were measured.

[0034]

[0035] Examples 1-3 demonstrate optimal synergy between the components and processes. A specific gelling system and autoclaving produce high-strength, stable hydration products. The structural water-repellent agent effectively blocks capillary channels, and the fiber blend and aggregate gradation provide excellent mechanical and durability properties.

[0036] Comparative Example 1: An excessively low water-cement ratio resulted in an overly dry and hard slurry, hindering effective molding and densification. Numerous defects and internal pores significantly reduced strength and resistance to impermeability and corrosion. Comparative Example 2: An excessively high water-cement ratio caused the slurry to bleed water. After evaporation, more capillary channels remained, leading to a porous material and a comprehensive decline in all properties. Comparative Example 3: Lacking a structural hydrophobic composite agent, the material reverted to a common hydrophilic matrix, resulting in a dramatic increase in water absorption. This made it more susceptible to penetration by acidic media, leading to dissolution and expansion damage. Comparative Example 4: Ordinary silicate cement produced numerous and unstable hydration products, making it easily eroded by acid. The lack of nanoscale fillers resulted in a porous structure and poor strength and acid resistance. Comparative Example 5: Containing only flexible polypropylene fibers and lacking the rigid support of high-modulus basalt fibers, the material's flexural strength and abrasion resistance decreased, and its crack inhibition ability weakened. Comparative Example 6: The presence of numerous voids between the single-graded aggregates required more cementitious slurry to fill, leading to unevenness and more weak areas. Poor density directly resulted in a comprehensive deterioration of strength, abrasion resistance, and impermeability. Comparative Example 7, with standard curing, failed to induce a deep pozzolanic reaction in metakaolin and silica fume. The hydration products were primarily low-strength gels with a porous and unstable structure, resulting in a comprehensive reduction in performance. Comparative Example 8 retained its internal properties, but the surface and shallow pores were not effectively sealed by the sodium silicate gel, leading to significant shortcomings in wear resistance and acid resistance. Comparative Example 9, after curing, was directly impregnated. Free water within the pores hindered effective solution penetration, and the sodium silicate only formed a physically attached, porous, and brittle film on the surface, failing to achieve deep strengthening.

[0037] Those skilled in the art should understand that the discussion of any of the above embodiments is merely exemplary; within the framework of this invention, the technical features of the above embodiments or different embodiments can also be combined, the steps can be implemented in any order, and there are many other variations of the different aspects of the invention as described above, which are not provided in detail for the sake of brevity.

[0038] This invention is intended to cover all such substitutions, modifications, and variations that fall within the broad scope of the appended claims. Therefore, any omissions, modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this invention should be included within the scope of protection of this invention.

Claims

1. A fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet, characterized in that, The components include the following parts by weight: The composition includes 45-60 parts of cementitious composite system, 4-7 parts of composite agent, 30-38 parts of graded aggregate system, 2.0-4.0 parts of mixed fiber reinforced network, 0.4-0.8 parts of chemical admixture, and water; The cementitious composite system consists of sulfoaluminate cement, metakaolin, and silica fume, with a mass ratio of (5.5~6.5):(2.5~3.5):

1. The composite agent is prepared by premixing nano-silica with silane coupling agent surface modification, calcium stearate and lithium slag powder in a mass ratio of (0.8~1.2):1:(3.5~4.5); The graded aggregate system is composed of 40-70 mesh quartz sand, 70-140 mesh quartz sand and 200-400 mesh quartz powder in a mass ratio of 1:(1.4-1.6):(0.6-0.8); The hybrid fiber reinforced network is composed of polypropylene fibers with a length of 8-12 mm and basalt fibers with a length of 10-15 mm, with a mass ratio of (1.5-2.5):

1. The water usage is such that the ratio of water to the total mass of the cementitious material composite system is 0.23 to 0.

26.

2. The fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet according to claim 1, characterized in that, The silane coupling agent is γ-aminopropyltriethoxysilane.

3. The fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet according to claim 1, characterized in that, The chemical admixture is a polycarboxylate superplasticizer.

4. The fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet according to claim 1, characterized in that, The mass ratio of sulfoaluminate cement, metakaolin, and silica fume in the cementitious composite system is 6:3:

1.

5. The fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet according to claim 1, characterized in that, In the composite agent, the mass ratio of silane coupling agent-modified nano-silica, calcium stearate, and lithium slag powder is 1:1:

4.

6. The fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet according to claim 1, characterized in that, In the hybrid fiber reinforced network, the mass ratio of polypropylene fiber to basalt fiber is 2:

1.

7. A method for preparing fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheets as described in any one of claims 1-6, characterized in that, Includes the following steps: Step S1: The nano-silica powder is surface modified with a silane coupling agent, and then mixed with calcium stearate and lithium slag powder to obtain the composite agent; Step S2: Dry mix the cementitious material composite system, graded aggregate system, composite agent and chemical additive obtained in step S1 according to the proportions in claim 1, add 70% to 75% of the total water volume for wet mixing to obtain a slurry, add the mixed fiber reinforced network and disperse it evenly, then add the remaining water and stir to obtain a fiber reinforced slurry, and vacuum roll-press the fiber reinforced slurry to obtain a wet blank; Step S3: After pre-curing the wet blank obtained in step S2 with hot and wet heat, demold it and then perform high temperature and high pressure steam curing. Step S4: Dry the semi-finished product obtained in step S3 at 60~80℃ to constant weight, then perform surface treatment with sodium silicate solution, and after natural curing, the finished product is obtained.

8. The method for preparing the fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet according to claim 7, characterized in that, In step S2, the vacuum degree during vacuum roll forming is not lower than -0.085MPa.

9. The method for preparing the fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet according to claim 7, characterized in that, In step S3, the high-temperature and high-pressure steam curing process is as follows: the temperature is raised to 180-190℃ and the pressure is 1.2-1.4 MPa within 1.5-2.5 hours, and the temperature and pressure are maintained at this condition for 8-12 hours. Then, the temperature is lowered to below 60℃ and normal pressure within no less than 2.5 hours.

10. The method for preparing the fireproof, moisture-proof, wear-resistant, and corrosion-resistant inorganic sheet according to claim 7, characterized in that, In step S4, the concentration of the sodium silicate aqueous solution is 0.5~2 mol / L, and the surface treatment method is immersion.

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