Fiber-reinforced veneered wood-based composite panel and magnesium sulfate system preparation process thereof

Abstract

The application discloses a fiber-reinforced veneered wood-based composite board, which adopts a magnesium sulfate system cementing material, and is prepared according to a magnesium sulfate system preparation process including the following steps: preparing a magnesium sulfate solution, preparing a cement paste, manually forming and curing, with 25kg of lightly calcined magnesium oxide as a reference ingredient, and according to use scenes including an inner wall board, an outer wall board and a floor board. The application has the advantages that a set of differentiated magnesium sulfate formula suitable for the inner wall, the outer wall and the floor board at the same time is provided; 18cm-thick board manual forming without cracking, deformation and stable strength is realized; and the board has the properties of A-grade fireproofing, light weight, high strength, water resistance, environmental protection and non-toxicity.

Description

Technical Field

[0001] This invention relates to the field of prefabricated building materials technology, specifically to a fiber-reinforced clad wood-based composite board and its magnesium sulfate system preparation process. Background Technology

[0002] Currently, the commonly used cladding materials for prefabricated wood-based structures are mainly gypsum board, calcium silicate board, and magnesium oxychloride cement board, which have the following shortcomings:

[0003] 1. Gypsum board has a low fire resistance rating, poor water resistance, and is prone to moisture damage, deformation, and mold growth, making it unsuitable for exterior walls and damp environments;

[0004] 2. Ordinary calcium silicate boards have high density, high brittleness, and poor compatibility with wood-based composites;

[0005] 3. Traditional magnesium oxychloride cement boards are prone to efflorescence, blooming, and corrosion of wood and metal framing, resulting in a short service life;

[0006] 4. Existing magnesium oxysulfate board formulations have poor versatility and cannot simultaneously meet the differentiated needs of interior wall decoration, exterior wall weather resistance, and high-strength flexural strength of floor slabs;

[0007] 5. When manually forming 18cm thick plates, problems such as cracking, deformation, and unstable strength are prone to occur.

[0008] Therefore, this invention provides a special magnesium sulfate system formula, which is optimized for interior walls, exterior walls, and floor slabs respectively, to achieve no efflorescence, no cracking, high water resistance, and suitability for manual production.

[0009] The information disclosed in this background section is intended only to enhance the understanding of the overall background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0010] The technical problem to be solved by this invention is to overcome the above-mentioned technical defects and provide a fiber-reinforced clad wood-based composite board and its magnesium sulfate system preparation process, overcoming the defects of traditional magnesium boards such as efflorescence, blooming, and wood corrosion; providing a set of differentiated magnesium sulfate formulas that can be applied to interior walls, exterior walls, and floor slabs; achieving 18cm thick boards that are hand-formed without cracking, deformation, and with stable strength; and making the boards have A-grade fire resistance, lightweight, high strength, water resistance, and environmental friendliness and non-toxicity.

[0011] To address the aforementioned issues, the present invention provides a fiber-reinforced clad wood-based composite board. The composite board utilizes a magnesium sulfate-based cementitious material, with 25 kg of lightly calcined magnesium oxide as the base material. Depending on the application scenario, it can be used as an interior wall panel, exterior wall panel, or floor slab.

[0012] Preferably, the formulation of the interior wall panel includes the following raw materials: 25.00 kg of lightly calcined magnesium oxide, 30.00 kg of magnesium sulfate heptahydrate, 45.00 kg of water, 8.75 kg of heavy calcium carbonate or talc, 0.88 kg of chopped glass fiber, 0.23 kg of high-efficiency water-reducing agent, 0.38 kg of waterproof and densifying agent, 0.25 kg of toughening and crack-resistant agent, 0.18 kg of anti-alkali return agent, and 0.05 kg of retarding regulator, wherein heavy calcium carbonate or talc and chopped glass fiber are used as fillers.

[0013] Preferably, the formulation of the exterior wall panel includes the following raw materials: 25.00 kg of lightly calcined magnesium oxide, 28.75 kg of magnesium sulfate heptahydrate, 42.50 kg of water, 10.00 kg of heavy calcium carbonate or talc powder, 10.00 kg of quartz powder, 1.00 kg of chopped glass fiber, 0.25 kg of high-efficiency water-reducing agent, 0.63 kg of waterproofing and densifying agent, 0.38 kg of toughening and crack-resistant agent, 0.25 kg of anti-alkali return agent, and 0.08 kg of retarding regulator, wherein heavy calcium carbonate or talc powder, quartz powder, and chopped glass fiber are used as fillers.

[0014] Preferably, the floor slab formulation includes the following raw materials: 25.00 kg of lightly calcined magnesium oxide, 27.50 kg of magnesium sulfate heptahydrate, 41.00 kg of water, 11.25 kg of heavy calcium carbonate or talc powder, 11.25 kg of quartz powder, 1.13 kg of chopped glass fiber, 0.30 kg of high-efficiency water-reducing agent, 0.50 kg of waterproofing and densifying agent, 0.50 kg of toughening and crack-resistant agent, 0.20 kg of anti-alkali reversion agent, and 0.08 kg of retarding regulator, wherein heavy calcium carbonate or talc powder, quartz powder, and chopped glass fiber are used as fillers.

[0015] This invention also discloses a process for preparing a magnesium sulfate system for fiber-reinforced veneered wood-based composite boards, comprising the following steps:

[0016] Step 1: Dissolve magnesium sulfate heptahydrate in water and stir until completely dissolved to obtain a magnesium sulfate solution. Control the temperature at 25-35℃ and the Baume degree at 23-26 Bé.

[0017] Step 2: Add lightly calcined magnesium oxide to the magnesium sulfate solution and stir for 2-3 minutes until uniform. Then add filler, water-reducing agent, waterproofing and sealing agent, toughening and crack-resistant agent, anti-alkali return agent, and retarding regulator in sequence. Finally, add chopped glass fiber and stir to obtain slurry.

[0018] Step 3: Manually pour the slurry onto the wooden substrate, smooth it, and compact it into shape. For a thickness of 18cm, you can lay fiberglass mesh in the middle for reinforcement.

[0019] Step 4: Initial setting time 40-60 minutes, demolding time 4-6 hours;

[0020] Step 5: Curing for 7 days at a temperature of 25-35℃ and a humidity of 60-70%.

[0021] Preferably, the chopped glass fiber has a length of 8 to 12 cm.

[0022] Preferably, the fire resistance rating of the board reaches Class A non-combustible, the flexural strength of the inner wall panel is ≥8MPa, the flexural strength of the outer wall panel is ≥10MPa, the flexural strength of the floor slab is ≥12MPa, there is no efflorescence or frost, and it does not corrode the wood substrate and is firmly bonded.

[0023] The advantages of this invention compared to existing technologies are:

[0024] 1. The fiber-reinforced wood-based composite board prepared by this invention does not exhibit efflorescence, blooming, or corrosion of wood, thus completely solving the common problems of traditional magnesium oxychloride boards;

[0025] 2. The magnesium sulfate system preparation process of this invention has one system with three formulations to meet the different performance requirements of interior walls, exterior walls and floor slabs respectively;

[0026] 3. The fiber-reinforced wood-based composite board prepared by this invention is suitable for 18cm handmade boards, and does not crack, deform, or have a high yield.

[0027] 4. The fiber-reinforced wood-based composite board prepared by this invention is Class A non-combustible and fireproof, with high strength, good water resistance, and is lightweight and environmentally friendly.

[0028] 5. The fiber-reinforced clad wood-based composite board prepared by this invention has excellent compatibility with wood-based structures and is particularly suitable for wood-based prefabricated buildings. Detailed Implementation

[0029] To make the content of this invention easier to understand, the technical solutions in the embodiments of this invention will be clearly and completely described below in conjunction with the embodiments of this invention.

[0030] Example 1

[0031] Interior wall panel formulation and preparation process

[0032] The formula for the interior wall panel includes the following raw materials: 25.00 kg of lightly calcined magnesium oxide, 30.00 kg of magnesium sulfate heptahydrate, 45.00 kg of water, 8.75 kg of heavy calcium carbonate or talc powder, 0.88 kg of chopped glass fiber, 0.23 kg of high-efficiency water-reducing agent, 0.38 kg of waterproof and densifying agent, 0.25 kg of toughening and crack-resistant agent, 0.18 kg of anti-alkali return agent, and 0.05 kg of retarding regulator.

[0033] The manufacturing process of interior wall panels includes the following steps:

[0034] Step 1: Dissolve magnesium sulfate heptahydrate in water and stir until completely dissolved to obtain a magnesium sulfate solution. Control the temperature at 25-35℃ and the Baume degree at 23-26 Bé.

[0035] Step 2: Add lightly calcined magnesium oxide to the magnesium sulfate solution and stir for 2-3 minutes until uniform. Then add heavy calcium carbonate or talc powder, chopped glass fiber, water-reducing agent, waterproofing and sealing agent, toughening and crack-resistant agent, anti-alkali return agent, and retarding regulator in sequence. Finally, add chopped glass fiber and stir to obtain slurry.

[0036] Step 3: Manually pour the slurry onto the wooden substrate, smooth it, and compact it into shape. For a thickness of 18cm, you can lay fiberglass mesh in the middle for reinforcement.

[0037] Step 4: Initial setting time 40-60 minutes, demolding time 4-6 hours;

[0038] Step 5: Curing for 7 days at a temperature of 25-35℃ and a humidity of 60-70%.

[0039] Example 2

[0040] Exterior wall panel formulation and preparation process

[0041] The formula for the exterior wall panel includes the following raw materials: 25.00 kg of lightly calcined magnesium oxide, 28.75 kg of magnesium sulfate heptahydrate, 42.50 kg of water, 10.00 kg of heavy calcium carbonate or talc powder, 10.00 kg of quartz powder, 1.00 kg of chopped glass fiber, 0.25 kg of high-efficiency water-reducing agent, 0.63 kg of waterproof and densifying agent, 0.38 kg of toughening and crack-resistant agent, 0.25 kg of anti-alkali return agent, and 0.08 kg of retarding regulator.

[0042] The manufacturing process of exterior wall panels includes the following steps:

[0043] Step 1: Dissolve magnesium sulfate heptahydrate in water and stir until completely dissolved to obtain a magnesium sulfate solution. Control the temperature at 25-35℃ and the Baume degree at 23-26 Bé.

[0044] Step 2: Add lightly calcined magnesium oxide to the magnesium sulfate solution and stir for 2-3 minutes until uniform. Then add heavy calcium carbonate or talc powder, quartz powder, chopped glass fiber, water-reducing agent, waterproofing and sealing agent, toughening and crack-resistant agent, anti-alkali return agent, and retarding regulator in sequence. Finally, add chopped glass fiber and stir to obtain slurry.

[0045] Step 3: Manually pour the slurry onto the wooden substrate, smooth it, and compact it into shape. For a thickness of 18cm, you can lay fiberglass mesh in the middle for reinforcement.

[0046] Step 4: Initial setting time 40-60 minutes, demolding time 4-6 hours;

[0047] Step 5: Curing for 7 days at a temperature of 25-35℃ and a humidity of 60-70%.

[0048] Example 3

[0049] Floor slab formulation and preparation process

[0050] The floor slab formulation includes the following raw materials: 25.00 kg of lightly calcined magnesium oxide, 27.50 kg of magnesium sulfate heptahydrate, 41.00 kg of water, 11.25 kg of heavy calcium carbonate or talc powder, 11.25 kg of quartz powder, 1.13 kg of chopped glass fiber, 0.30 kg of high-efficiency water-reducing agent, 0.50 kg of waterproofing and densifying agent, 0.50 kg of toughening and crack-resistant agent, 0.20 kg of anti-alkali return agent, and 0.08 kg of retarding regulator.

[0051] The fabrication process of the floor slab includes the following steps:

[0052] Step 1: Dissolve magnesium sulfate heptahydrate in water and stir until completely dissolved to obtain a magnesium sulfate solution. Control the temperature at 25-35℃ and the Baume degree at 23-26 Bé.

[0053] Step 2: Add lightly calcined magnesium oxide to the magnesium sulfate solution and stir for 2-3 minutes until uniform. Then add heavy calcium carbonate or talc powder, quartz powder, chopped glass fiber, water-reducing agent, waterproofing and sealing agent, toughening and crack-resistant agent, anti-alkali return agent, and retarding regulator in sequence. Finally, add chopped glass fiber and stir to obtain slurry.

[0054] Step 3: Manually pour the slurry onto the wooden substrate, smooth it, and compact it into shape. For a thickness of 18cm, you can lay fiberglass mesh in the middle for reinforcement.

[0055] Step 4: Initial setting time 40-60 minutes, demolding time 4-6 hours;

[0056] Step 5: Curing for 7 days at a temperature of 25-35℃ and a humidity of 60-70%.

[0057] Performance indicators

[0058] Fire rating of fiber-reinforced veneered wood-based composite board: Class A, non-combustible;

[0059] Water absorption rate of fiber-reinforced veneered wood-based composite board: ≤15%;

[0060] Fiber-reinforced veneered wood composite board: No efflorescence or blooming.

[0061] Water resistance of fiber-reinforced veneered wood composite board (72h immersion): no softening, no delamination, no detachment;

[0062] Fiber-reinforced veneered wood-based composite board compatibility with wood matrix: non-corrosive and firmly bonded;

[0063] Flexural strength of interior walls: ≥8 MPa;

[0064] External wall flexural strength: ≥10 MPa;

[0065] Floor slab flexural strength: ≥12 MPa.

[0066] The present invention and its embodiments have been described above, and such description is not restrictive. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the invention, such designs should fall within the protection scope of the present invention.

Claims

1. A fiber-reinforced veneered wood-based composite board, characterized in that, The composite panel uses magnesium sulfate-based cementitious materials, with 25 kg of lightly calcined magnesium oxide as the standard for batching. Depending on the application scenario, it includes interior wall panels, exterior wall panels, and floor slabs.

2. The fiber-reinforced veneered wood-based composite board according to claim 1, characterized in that: The formulation of the interior wall panel includes the following raw materials: 25.00 kg of lightly calcined magnesium oxide, 30.00 kg of magnesium sulfate heptahydrate, 45.00 kg of water, 8.75 kg of heavy calcium carbonate or talc, 0.88 kg of chopped glass fiber, 0.23 kg of high-efficiency water-reducing agent, 0.38 kg of waterproof and densifying agent, 0.25 kg of toughening and crack-resistant agent, 0.18 kg of anti-alkali return agent, and 0.05 kg of retarding regulator, wherein heavy calcium carbonate or talc and chopped glass fiber are used as fillers.

3. The fiber-reinforced veneered wood-based composite board according to claim 1, characterized in that: The formula of the exterior wall panel includes the following raw materials: 25.00 kg of lightly calcined magnesium oxide, 28.75 kg of magnesium sulfate heptahydrate, 42.50 kg of water, 10.00 kg of heavy calcium carbonate or talc powder, 10.00 kg of quartz powder, 1.00 kg of chopped glass fiber, 0.25 kg of high-efficiency water-reducing agent, 0.63 kg of waterproof and densifying agent, 0.38 kg of toughening and crack-resistant agent, 0.25 kg of anti-alkali return agent, and 0.08 kg of retarding regulator, wherein heavy calcium carbonate or talc powder, quartz powder, and chopped glass fiber are used as fillers.

4. The fiber-reinforced veneered wood-based composite board according to claim 1, characterized in that: The floor slab formulation includes the following raw materials: 25.00 kg of lightly calcined magnesium oxide, 27.50 kg of magnesium sulfate heptahydrate, 41.00 kg of water, 11.25 kg of heavy calcium carbonate or talc powder, 11.25 kg of quartz powder, 1.13 kg of chopped glass fiber, 0.30 kg of high-efficiency water-reducing agent, 0.50 kg of waterproofing and densifying agent, 0.50 kg of toughening and crack-resistant agent, 0.20 kg of anti-alkali return agent, and 0.08 kg of retarding regulator, wherein heavy calcium carbonate or talc powder, quartz powder, and chopped glass fiber are used as fillers.

5. The preparation process of the magnesium sulfate system for fiber-reinforced veneered wood-based composite board according to any one of claims 1-4, characterized in that, Includes the following steps: Step 1: Dissolve magnesium sulfate heptahydrate in water and stir until completely dissolved to obtain a magnesium sulfate solution. Control the temperature at 25-35℃ and the Baume degree at 23-26 Bé. Step 2: Add lightly calcined magnesium oxide to the magnesium sulfate solution and stir for 2-3 minutes until uniform. Then add filler, water-reducing agent, waterproofing and sealing agent, toughening and crack-resistant agent, anti-alkali return agent, and retarding regulator in sequence. Finally, add chopped glass fiber and stir to obtain slurry. Step 3: Manually pour the slurry onto the wooden substrate, smooth it, and compact it into shape. For a thickness of 18cm, you can lay fiberglass mesh in the middle for reinforcement. Step 4: Initial setting time 40-60 minutes, demolding time 4-6 hours; Step 5: Curing for 7 days at a temperature of 25-35℃ and a humidity of 60-70%.

6. The preparation process of the magnesium sulfate system according to claim 5, characterized in that: The chopped glass fibers have a length of 8–12 cm.

7. The fiber-reinforced clad wood-based composite board according to claim 1, characterized in that: The fire resistance rating of the boards reaches Class A non-combustible, the flexural strength of the interior wall panels is ≥8MPa, the flexural strength of the exterior wall panels is ≥10MPa, the flexural strength of the floor slabs is ≥12MPa, there is no efflorescence or frost, and they do not corrode the wood substrate and are firmly bonded.