Sandwich fiber mesh composited inorganic board and preparation method therefor

Abstract

A sandwich fiber mesh composited inorganic board and a preparation method therefor. A high-elasticity sandwich fiber mesh is prepared by means of a melt-blowing method, an inorganic slurry is poured to fully fill through pores of the high-elasticity sandwich fiber mesh, and after shaping and curing, the sandwich fiber mesh composited inorganic board having significantly improved properties is prepared.

Description

Sandwiched fiber web composite inorganic board and preparation method thereof

[0001] The present application claims priority to the Chinese patent application No. CN202410866831.0, filed on June 28, 2024, and entitled "Sandwiched fiber web composite inorganic board and preparation method thereof", the content of which is incorporated herein by reference. TECHNICAL FIELD

[0002] The present disclosure relates to, but is not limited to, the field of building materials, and more particularly to, but is not limited to, sandwiched fiber web, sandwiched fiber web composite inorganic board and preparation method thereof. BACKGROUND

[0003] Polymer extrusion melt-blown into porous nonwoven fabrics are widely used in civil engineering, medical and health care, agriculture, clothing, packaging, sound insulation and other fields, playing the role of reinforcement, isolation, filtration, and anti-seepage. For example, geonet and geogrid, geomembrane, protective clothing in the health industry, disinfection cloth, mask, diaper, household cloth, wiping cloth, wet tissue, magic towel, soft towel roll, beauty product, sanitary napkin, automobile sound insulation, sofa, agricultural seedling bed, oil absorption material, etc. The raw materials can be selected from a wide range, including thermoplastic polymers (such as polycarbonate, polyester, polyamide, polyurethane), block copolymers (such as styrene-butadiene-styrene and styrene-isoprene-styrene block copolymers), and polyolefins (such as modified polypropylene, modified polybutylene, and modified polyamylene). Examples of materials that can be used to make melt-blown fibers are disclosed in U.S. Patent No. 5,706,804 to Baumann et al.; U.S. Patent No. 4,419,993 to Peterson; U.S. Reissued Patent No. Re. 28,102 to Mayhew; U.S. Patent Nos. 5,472,481 and 5,411,576 to Jones et al.; and U.S. Patent No. 5,908,598 to Rousseau et al. Chinese Patent Application No. 201610222859.6, Chinese Application No. 202310369306.3, Chinese Application No. 201620217204.5, and the like disclose the preparation of three-dimensional porous fiber cloth from polyamide melt-blown.

[0004] The existing house inner partition wall is usually made of light steel keel and gypsum board by on-site construction. The existing gypsum board has poor impact resistance, and only the surface paper provides toughness, and the inner layer of the surface paper is brittle gypsum, which has a great weakness of low nail holding force. The conventional screw is not convenient to hang heavy objects on the surface of the gypsum board, and the gypsum board also needs to be vertically carried during transportation, otherwise it is easy to break. The method of mixing glass fiber into gypsum powder has very limited effect, and cannot fundamentally solve the toughness and strength problems of the gypsum board. Similarly, although the method of sinking glass mesh into the core of the gypsum board or bonding glass cloth on the surface of the gypsum board can improve the strength of the gypsum board to a certain extent, the performance improvement is still limited because the glass fiber is only layered and bonded with the gypsum. For example, when the length of the glass fiber mixed into the gypsum powder is 10mm to 25mm, the diameter is 10μm to 20μm, and the weight ratio is 1.2% to 3.0%, the maximum value of the nail holding force and the bending strength is obtained, and the maximum improvement is about 10% to 30%. However, the method of sinking glass mesh into the core of the gypsum board or bonding glass cloth on the surface of the gypsum board is difficult to improve the nail holding force and mechanical strength by more than 50%. Especially for the fiber filling process, the strength decreases with the increase of the fiber content, mainly because the fiber aggregation is difficult to disperse with the increase of the fiber content.

[0005] SUMMARY

[0006] The following is a summary of the subject matter of the detailed description. This summary is not intended to limit the scope of the claims.

[0007] The first aspect of the present application provides a sandwiched fiber web, which comprises a middle web and three-dimensional fiber webs arranged on the upper and lower sides of the middle web respectively, forming a sandwich structure of three-dimensional fiber web-middle web-three-dimensional fiber web.

[0008] The second aspect of the present application provides a preparation method of the above-mentioned sandwiched fiber web, comprising:

[0009] forming a three-dimensional fiber web by melt blowing the polymer raw material;

[0010] spraying adhesive on one side surface of the middle web;

[0011] the side of the middle web sprayed with adhesive is in contact with the three-dimensional fiber web and the middle web is arranged on the three-dimensional fiber web;

[0012] spraying adhesive on the other side surface of the middle web;

[0013] continuing to melt blow the polymer raw material on the other side surface of the middle web sprayed with adhesive until a sandwich structure of three-dimensional fiber web-middle web-three-dimensional fiber web is formed;

[0014] pressing and curing the sandwich structure to bond the sandwich structure into one.

[0015] The third aspect of the present application provides a sandwich web composite inorganic board, which comprises a core layer and face layer paper on the upper and lower sides of the core layer.

[0016] The fourth aspect of the present application provides a preparation method of the above sandwich web composite inorganic board, which comprises slurry injection, slurry shaping, face layer paper compounding, solidification drying and cutting and packaging.

[0017] The fifth aspect of the present application provides a sandwich web composite inorganic board prepared by the above method.

[0018] Other aspects can become apparent from the following drawings and detailed description.

[0019] SUMMARY

[0020] The accompanying drawings are included to provide a further understanding of the present application, and constitute a part of this specification, illustrate embodiments of the present application, and are used to explain the technical solutions of the present application, and do not constitute a limitation on the technical solutions of the present application.

[0021] Fig. 1 is a structural schematic diagram of a sandwich web of the present application;

[0022] Fig. 2 is a partial enlarged view of Fig. 1;

[0023] Fig. 3 is a structural schematic diagram of a sandwich web composite inorganic board of the present application;

[0024] Fig. 4 is a partial enlarged view of Fig. 3;

[0025] Fig. 5 is a production process schematic diagram of a sandwich web composite inorganic board of the present application;

[0026] Fig. 6 is another production process schematic diagram of a sandwich web composite inorganic board of the present application.

[0027] Among them, the reference signs are as follows:

[0028] 1: three-dimensional web; 2: middle web; 3: face layer paper; 4: slurry pipe; 5: first upper pressing roller; 6: vibrating belt; 7: upper paper roller; 8: lower paper roller; 9: upper face paper; 10: lower face paper; 11: third upper pressing roller; 12: third lower pressing roller; 13: fourth lower pressing roller; 14: fourth upper pressing roller; 15: fifth lower pressing roller; 16: fifth upper pressing roller; 17. sixth lower pressing roller; 18. inorganic slurry.

[0029] DETAILED DESCRIPTION

[0030] The first aspect of the present application provides a sandwiched web, comprising a middle web and a three-dimensional web, which are respectively arranged on the upper and lower sides of the middle web, forming a sandwich structure of three-dimensional web-middle web-three-dimensional web.

[0031] In an exemplary embodiment, the middle web is a single-layer web with a mesh opening size of 2 mm to 15 mm, for example, 2 mm, 4 mm, 6 mm, 8 mm, 10 mm, 12 mm, 14 mm or 15 mm, but not limited to the listed values, and other values not listed in this range are also applicable.

[0032] In an exemplary embodiment, the material of the middle web can be selected from at least one of metal fiber, glass fiber, chemical fiber and natural fiber.

[0033] Optionally, the fiber diameter of the middle web is 0.2 mm to 2 mm, for example, 0.2 mm, 0.6 mm, 1.0 mm, 1.4 mm, 1.8 mm or 2 mm, but not limited to the listed values, and other values not listed in this range are also applicable.

[0034] In an exemplary embodiment, the three-dimensional web is a three-dimensional network structure formed by randomly oriented fibers adhering to each other, wherein the three-dimensional web has through pores.

[0035] Optionally, the fiber diameter of the three-dimensional web is 10 μm to 200 μm.

[0036] Optionally, the average fiber spacing of the three-dimensional web is 0.3 mm to 8 mm.

[0037] In an exemplary embodiment, the thickness of the three-dimensional web is 3 mm to 20 mm.

[0038] In an exemplary embodiment, the material of the three-dimensional web can be selected from any one or more of polyamide, polylactic acid, polypropylene, polyester-based elastomer, polycarbonate, modified polypropylene and polypropylene copolymer, polystyrene and modified polystyrene, polyphenylene sulfide, polyethylene terephthalate, modified polyethylene terephthalate, polyurethane.

[0039] In an exemplary embodiment, the sandwiched web further comprises a binder sprayed on the surface of the middle web.

[0040] In an exemplary embodiment, the binder can be selected from at least one of epoxy resin, phenolic resin, polyvinyl alcohol copolymer resin, polylactate, polyacrylate copolymer, polystyrene copolymer resin, polyacrylonitrile copolymer resin, polyvinyl acetate, polyamide-based hot melt adhesive.

[0041] In an exemplary embodiment, the polyamide-based hot melt adhesive can be a polyurethane hot melt adhesive.

[0042] The second aspect of the present application provides a method for preparing the sandwiched web as described above, comprising:

[0043] forming a three-dimensional web by melt-blowing the polymer raw material;

[0044] spraying adhesive on one side surface of the middle web;

[0045] contacting the side of the middle web sprayed with adhesive with the three-dimensional web and laying the middle web on the three-dimensional web;

[0046] spraying adhesive on the other side surface of the middle web;

[0047] continuing melt-blowing the polymer raw material on the other side surface of the middle web sprayed with adhesive until a sandwiched structure of three-dimensional web-middle web-three-dimensional web is formed;

[0048] pressing and curing the sandwiched structure until the sandwiched structure is bonded together.

[0049] In an exemplary embodiment, the polymer raw material is one or more polymers.

[0050] In an exemplary embodiment, the melt-blowing comprises:

[0051] heating and melting the polymer raw material through an extruder to form a melt;

[0052] blowing and refining the melt into fibers through a high-speed hot air stream blown out of a hole arranged near the nozzle and gathered on a continuously running web-receiving belt to form a three-dimensional web with good resilience.

[0053] In an exemplary embodiment, the temperature of the extruder is 260°C to 310°C.

[0054] In an exemplary embodiment, the melt-blowing die comprises a plurality of nozzles, and the diameter of the nozzles is 0.05mm to 1.2mm;

[0055] Optionally, the pressure of the melt-blowing die is 0.2MPa to 1.2MPa;

[0056] Optionally, the temperature of the melt-blowing die is 195°C to 265°C,

[0057] Optionally, the air pressure is 15kMPa to 28kMPa.

[0058] In an exemplary embodiment, the melt-blowing further comprises melt-blowing or controlling intermittent melt-blowing of the two or more polymer raw materials simultaneously, comprising the steps of:

[0059] heating and melting the two or more polymer raw materials in different twin-screw extruders respectively to form two or more melts;

[0060] arranging the orifices of the melt-blowing die of the two or more melts at an angle, and the two or more melts are blown out through the respective melt-blowing die to form fibers, and are blown and refined by high-speed hot air flow to form a three-dimensional web with good resilience on a continuously running web-receiving belt.

[0061] In an exemplary embodiment, the temperature of the solidification is 110-200°C, for example, 110°C, 130°C, 150°C, 170°C, 190°C or 200°C, but is not limited to the listed values, and other values not listed in this range are also applicable.

[0062] The third aspect of the present application provides a sandwich web composite inorganic panel, which comprises a core layer and a face layer paper on the upper and lower sides of the core layer.

[0063] In an exemplary embodiment, the core layer comprises the sandwich web and an inorganic slurry, wherein the inorganic slurry fills the pores of the sandwich web and solidifies.

[0064] In an exemplary embodiment, the inorganic slurry is a pumpable slurry with fluidity formed by mixing and stirring semi-hydrated gypsum and Portland cement as main raw materials with water.

[0065] In an exemplary embodiment, the raw materials of the inorganic slurry comprise, by weight fraction, 50-85 parts of semi-hydrated gypsum, 3-25 parts of Portland cement, 2-10 parts of waste paper slurry, 2-13 parts of filler, 0.5-3 parts of industrial starch and 0.5-5 parts of auxiliary agent.

[0066] In an exemplary embodiment, the filler comprises any one or more of lime, fly ash and calcium carbonate.

[0067] In an exemplary embodiment, the auxiliary agent comprises any one or more of water-reducing agent, coagulation regulator and foaming agent.

[0068] In an exemplary embodiment, the water-reducing agent is selected from any one or more of aliphatic water-reducing agent, polycarboxylic acid water-reducing agent and naphthalene sulfonic acid water-reducing agent; preferably, selected from any one or more of potassium tartrate, acrylic acid and sodium acrylate, sulfonic acid styrene, isothiocyanate and naphthalene sulfonic acid.

[0069] In an exemplary embodiment, the coagulation regulator is selected from any one or more of dihydrate gypsum, calcium chloride, volcanic ash, sulfate; for example, the sulfate is calcium sulfate dihydrate.

[0070] In an exemplary embodiment, the foaming agent is selected from any one or more of sodium dodecyl sulfate, sodium fatty alcohol ether polyoxyethylene sulfate, sodium alpha-olefin sulfonate, hydrogen peroxide.

[0071] The fourth aspect of the present application provides a method for preparing the sandwiched fibrid composite inorganic panel, comprising slurry injection, slurry shaping, surface paper compounding, coagulation and drying, and cutting and packaging.

[0072] In an exemplary embodiment, the method comprises the following steps:

[0073] 1) slurry injection: the inorganic slurry is injected and filled into the pores of the sandwiched fibrid, forming an integrated continuous phase in which the sandwiched fibrid is embedded in the inorganic slurry;

[0074] 2) slurry shaping: the material obtained in step 1) is compacted and the excess inorganic slurry is scraped off and recycled;

[0075] 3) surface paper compounding: the lower and upper surfaces of the compacted material in step 2) are bonded and compounded with surface paper;

[0076] 4) coagulation, drying, cutting and packaging: the material in step 3) is coagulated, dried, cut and packaged to obtain a high-strength three-dimensional fibrid-reinforced sandwiched fibrid composite inorganic panel.

[0077] In an exemplary embodiment, step 1) comprises: the sandwiched fibrid is guided into a slurry injection section, and the inorganic slurry is injected into the sandwiched fibrid through a slurry pipe in the slurry injection section;

[0078] Optionally, in the slurry injection section, the slurry pipe is located above the sandwiched fibrid; a first upper compression roller is arranged on the upper surface of the material after slurry injection in the conveying direction of the sandwiched fibrid, and a vibration device and a first lower compression roller are arranged on the lower surface of the material, and the inorganic slurry enters the pores of the upper three-dimensional fibrid, the middle fibrid and the lower three-dimensional fibrid of the sandwiched fibrid in sequence through extrusion and vibration, forming an integrated continuous phase in which the sandwiched fibrid is embedded in the inorganic slurry.

[0079] In an exemplary embodiment, the vibration device is a vibrating belt, and a transmission roller is arranged in the vibrating belt to drive the vibrating belt to vibrate;

[0080] Optionally, the vibration frequency of the vibration device is 30-200 Hz.

[0081] In an exemplary embodiment, step 2) comprises: conveying the material in step 1) to a pulp shaping section for compaction;

[0082] Optionally, in the pulp shaping section, the upper surface and the lower surface of the material are respectively provided with a second upper compression roller and a second lower compression roller to ensure that the inorganic pulp fills the pores of the sandwiched fibrous web and scrapes off the excess inorganic pulp for recycling.

[0083] In an exemplary embodiment, step 3) comprises: conveying the material compacted in step 2) to a face paper compounding section; in the face paper compounding section, the upper surface and the lower surface of the material are respectively provided with an upper paper roller and a lower paper roller, and the same speed of the face paper released through the upper paper roller and the lower paper roller is respectively bonded and compounded with the upper surface and the lower surface of the material.

[0084] In an exemplary embodiment, after the face paper is compounded, the upper surface of the material is further provided with a third upper compression roller, a fourth upper compression roller, a fifth upper compression roller and a sixth upper compression roller in sequence; and the lower surface of the material is further provided with a third lower compression roller, a fourth lower compression roller, a fifth lower compression roller and a sixth lower compression roller in sequence.

[0085] The fifth aspect of the present application provides an inorganic board compounded with the sandwiched fibrous web prepared by the above method.

[0086] The present application has the following technical effects:

[0087] 1) The present application provides a sandwiched fibrous web formed by melt blowing, an inorganic board compounded with the sandwiched fibrous web and a forming method thereof, which solves the problem that the comprehensive strength of conventional fiber-reinforced inorganic boards is difficult to effectively improve;

[0088] 2) The melt blowing method is used to produce the sandwiched fibrous web, which has the characteristics of high resilience and mutually penetrating pores;

[0089] 3) The high-flow inorganic pulp is filled in the pores of the sandwiched fibrous web and forms a continuous phase, which fully maintains the strength of the inorganic board after the inorganic pulp is solidified and dried;

[0090] 4) The sandwiched fibrous web forms a three-dimensional fibrous web in the inorganic continuous phase, the fibers are connected to form a three-dimensional network, and the inorganic continuous phase is compounded into an integrated reinforcing structure, so that the comprehensive mechanical properties of the board such as bending resistance, impact resistance, tensile strength and compressive strength are fundamentally improved, and the nail holding force is improved by more than one time.

[0091] The embodiments of the present application will be described in detail below. In the case of no conflict, the embodiments in the present application and the features in the embodiments can be combined with each other at will.

[0092] The present application can use the following polymers to produce the non-woven three-dimensional fibrous web by the melt blowing process.

[0093] The present application will be further described in detail below with reference to specific embodiments, but these examples should not be construed as limiting the present application.

[0094] The raw materials used in the comparative examples and embodiments of this application are all commercially available products.

[0095] The inorganic slurry formulations in Examples 1 to 5 are shown in Table 1. The composition and weight ratio of the additives in Examples 1-5 are as follows:

[0096] Sodium acrylate: calcium chloride: styrene sulfonate: naphthalene ethanesulfonic acid: gypsum dihydrate: volcanic ash: calcium sulfate dihydrate: sodium dodecyl sulfate = 8:10:7:20:15:22:8:10.

[0097] Example 1

[0098] Inorganic sandwich fiber composite boards are prepared by combining inorganic slurry with nylon-based sandwich fiber webs. Specifically:

[0099] The grade of the nylon polymer is DuPont 70G15L. The preparation methods for nylon sandwich fiber webs include:

[0100] Nylon polymer raw materials are added to an extruder, and the extruder is heated to a temperature of 260°C to 310°C. The raw materials are melted and then conveyed to a meltblown die and pressurized to 0.3 MPa. The molten raw materials are sprayed out through multiple nozzles of the meltblown die, with the nozzle diameter ranging from 0.05 mm to 1.2 mm. Under the strong stretching of the high-temperature and high-speed airflow formed at a wind pressure of 25 kMPa, the material is meltblown and refined and aggregated onto a continuously operating take-up belt to form a three-dimensional fiber web with good resilience.

[0101] Adhesive is sprayed onto one side of the mesh; wherein the mesh is made of copper mesh with a diameter of 0.5 mm;

[0102] After continuing to melt-blown the molten material to achieve the desired thickness, the side of the mesh coated with adhesive comes into contact with the three-dimensional fiber mesh, and the mesh is then laid out on the three-dimensional fiber mesh.

[0103] Adhesive is sprayed onto the other side surface of the grille;

[0104] Continue to melt-spray the molten material onto the other side of the mesh that is coated with adhesive until a sandwich structure with a three-dimensional fiber mesh-mesh-three-dimensional fiber mesh is formed;

[0105] The sandwich fiber mesh is pressurized and cured until the sandwich structure is bonded together.

[0106] The adhesive sprayed onto the surface of the grille is polyurethane hot melt adhesive; the curing temperature is 160℃.

[0107] As shown in FIGS. 5-6, the preparation method of the sandwich web composite inorganic board comprises the following steps:

[0108] 1) Grouting: the sandwich web is guided into the grouting section, and the inorganic slurry is injected into the sandwich web through the slurry pipe 4; wherein, in the grouting section, the slurry pipe 4 is located above the sandwich web; a first upper compression roller 5 is further arranged on the upper surface of the material after grouting in the conveying direction of the sandwich web, and a vibrating belt 6 and a first lower compression roller (not shown) are arranged on the lower surface of the material, the inorganic slurry enters the pores of the upper three-dimensional web, the middle web and the lower three-dimensional web of the sandwich web in sequence through extrusion and vibration, forming an integrated continuous phase in which the sandwich web is embedded in the inorganic slurry. Wherein, the vibrating belt 6 is driven by a transmission roller, and the vibration frequency is 30-200 Hz.

[0109] 2) Slurry shaping: the material obtained in step 1) is conveyed to the slurry shaping section for compaction, the upper surface and the lower surface of the material are respectively provided with a second upper compression roller (not shown) and a second lower compression roller (not shown), to ensure that the inorganic slurry fills the pores of the sandwich web and scrapes off the excess inorganic slurry for recycling.

[0110] 3) Surface paper composite: the compacted material in step 2) is conveyed to the surface paper composite section, the upper surface and the lower surface of the material are respectively provided with an upper paper roller 7 and a lower paper roller 8, and the upper surface paper 9 and the lower surface paper 10 released at the same speed through the upper paper roller 7 and the lower paper roller 8 are respectively bonded and compounded with the upper surface and the lower surface of the material. As shown in FIGS. 5-6, after the surface paper composite, the upper surface of the material is further provided with a third upper compression roller 11, a fourth upper compression roller 14, a fifth upper compression roller 16 and a sixth upper compression roller (not shown) in sequence; the lower surface of the material is further provided with a third lower compression roller 12, a fourth lower compression roller 13, a fifth lower compression roller 15 and a sixth lower compression roller 17 in sequence.

[0111] 4) Solidification, drying, cutting and packaging: the material in step 3) is solidified, dried, cut and packaged to obtain a high-strength three-dimensional web reinforced sandwich web composite inorganic board.

[0112] Example 2

[0113] A sandwich web composite inorganic board is prepared by using inorganic slurry and sandwich web composite. Wherein:

[0114] The polylactic acid is Ingeo 6253D, a polyvinyl alcohol modified polylactic acid from Nanture Works, the die temperature is 195-210°C, the die pressure is 0.4 MPa, and the air pressure is 28 kMPa.

[0115] The rest is the same as example 1.

[0116] Example 3

[0117] An inorganic slurry was compounded with a modified polypropylene sandwich web to produce a sandwich web compounded inorganic board. Herein:

[0118] The modified polypropylene was a grade of BASELL HP5031 from Korea, the die temperature was 210 to 245℃, the die pressure was 0.2 MPa, and the air pressure was 18 kMPa.

[0119] The rest was the same as Example 1.

[0120] Example 4

[0121] An inorganic slurry was compounded with a polyethylene terephthalate sandwich web to produce a sandwich web compounded inorganic board. Herein:

[0122] The polyethylene terephthalate polymer was polyethylene terephthalate, a grade of DAK Americas PET C 9921 from USA, the die temperature was 225 to 255℃, the die pressure was 0.8 MPa, and the air pressure was 19 kMPa.

[0123] The rest was the same as Example 1.

[0124] Example 5

[0125] An inorganic slurry was compounded with a modified polyethylene terephthalate sandwich web to produce a sandwich web compounded inorganic board. Herein:

[0126] The modified polyethylene terephthalate polymer was modified polybutylene terephthalate, a grade of Ticona Celanex PBT 2008, the die temperature was 230 to 265℃, the die pressure was 1.2 MPa, and the air pressure was 15 kMPa.

[0127] The rest was the same as Example 1.

[0128] Example 6

[0129] An inorganic slurry of Example 1 was compounded with a nylon-polybutylene terephthalate melt blown composite three-dimensional web to produce a sandwich web compounded inorganic board. Herein:

[0130] The nylon was a grade of DuPont 70G15L from USA, the polybutylene terephthalate was a grade of DSM J-1860 / CF / 32 from USA, and the mass ratio of the two resins was 60:40, and each was dried at 130℃ for at least 4h;

[0131] The nylon raw material is heated in the first extruder, which is heated to 260-310°C and then delivered to the melt-blowing die of the first extruder. At this time, the die pressure is 0.3 MPa, the air pressure is 22 kPa, and the pulse frequency is 120 Hz.

[0132] The polybutylene terephthalate is heated in the second extruder, which is heated to 230-265°C and then delivered to the melt-blowing die of the second extruder. At this time, the die pressure is 0.3 MPa, the air pressure is 22 kPa, and the pulse frequency is 80 Hz.

[0133] The corresponding included angle of the nozzle holes of the melt-blowing die of the first extruder and the melt-blowing die of the second extruder is 45-50°, and the two kinds of short fibers are mixed into a three-dimensional fiber web by air flow.

[0134] The rest is the same as in Example 1.

[0135] Example 7

[0136] An inorganic slurry with the same ratio as in Example 4 and a polybutylene terephthalate-polyethylene terephthalate melt-blended three-dimensional fiber web are used to prepare an inorganic plate composite sandwiched with the fiber web. Among them:

[0137] The polyethylene terephthalate has the brand of DAK Americas C 99210, and the polybutylene terephthalate has the brand of DuPont Crastin S600F10 NC010. The two are mixed in a mass ratio of 60:40 and then fed into the extruder. The die temperature is 225-255°C, the die pressure is 0.6 MPa, and the air pressure is 20 kPa.

[0138] The rest is the same as in Example 1.

[0139] Table 1. Inorganic slurry ratio table

[0140] In the above Examples 6-7, the sandwiched fiber web is prepared by melt-blowing. The desired high-resilience three-dimensional porous fiber web can be obtained by melt-blowing two kinds of polymers simultaneously or by controlling intermittent melt-blowing.

[0141] The application can also be used to obtain the desired high-resilience three-dimensional porous fiber web by melt-blowing two or more kinds of polymers simultaneously or by controlling intermittent melt-blowing. The high-resilience sandwiched fiber web with crimped fibers can be obtained by matching the polymer variety, air delivery speed, temperature, and air hole angle, or by mixing and melting two or more kinds of polymers with different degrees of polymerization, graft-modified polymers, and block-modified polymer raw materials, or by separately melting and pumping to different dies for melt-blowing, and controlling different air delivery angles, pressures, and air temperatures to obtain the desired high-resilience three-dimensional through-porous fiber web.

[0142] Comparative Example 1

[0143] The same as Example 1, except that the board does not contain the scrim or glass fiber.

[0144] Comparative Example 2

[0145] The same as Example 1, except that the board contains 1.5wt% glass fiber.

[0146] Test:

[0147] The sandwich scrim composite inorganic board prepared in Examples 1-5 was tested, and the results are shown in Table 2.

[0148] Table 2. Performance of sandwich scrim composite inorganic board

[0149] It has been proven that the sandwich scrim composite inorganic board of the present application has more than doubled the nail holding force and more than 70% improved the bending strength compared with the scrim-free board. The bending strength test adopts the American standard ASTM C473-17, and the nail holding force test adopts the standard GB / T 14018-2009.

[0150] Conclusion: 1) The present application provides a sandwich scrim formed by melt blowing, a composite inorganic board and a forming method thereof, which solves the problem that the comprehensive strength of conventional fiber-reinforced inorganic board is difficult to effectively improve; 2) The sandwich scrim produced by melt blowing has high resilience and interpenetrating pore characteristics; 3) The inorganic slurry with high fluidity fills the pores in the sandwich scrim and the middle net pores to form a continuous phase, which fully maintains the strength of the inorganic board after the inorganic slurry is solidified and dried; 4) The sandwich scrim forms a three-dimensional scrim in the inorganic continuous phase, the fibers are connected to form a three-dimensional network, and the inorganic continuous phase is combined into an integrated reinforcing structure, which fundamentally improves the comprehensive mechanical properties of the board such as bending resistance, impact resistance, tensile strength, and compressive strength, and the nail holding force is more than doubled.

[0151] Although the embodiments of the present application have been shown and described above, it should be understood that the above embodiments are exemplary and should not be construed as limiting the present application, and those skilled in the art can make changes, modifications, replacements and variations to the above embodiments within the scope of the present application.

Claims

1. A sandwich fiber web composite inorganic board, the sandwich fiber web composite inorganic board comprising a core layer and surface paper located on the upper and lower sides of the core layer, the core layer comprising a sandwich fiber web and an inorganic pulp, wherein, The inorganic slurry fills the pores of the sandwich fiber mesh and solidifies; the sandwich fiber mesh includes a central mesh and a three-dimensional fiber mesh, with the three-dimensional fiber mesh respectively disposed on the upper and lower sides of the central mesh, forming a sandwich structure with a three-dimensional fiber mesh-central mesh-three-dimensional fiber mesh.

2. The inorganic board material with sandwich fiber mesh composite according to claim 1, wherein, The material of the mesh is selected from at least one of metal fiber, glass fiber, chemical fiber and natural fiber; The three-dimensional fiber web is a three-dimensional mesh structure formed by randomly oriented fibers bonded together, and the three-dimensional fiber web has through pores; Optionally, the material of the three-dimensional fiber web is selected from any one or more of polyamide, polylactic acid, polypropylene, polyester elastomers, polycarbonate, modified polypropylene and polypropylene copolymers, polystyrene and modified polystyrene, polyphenylene sulfide, polyethylene terephthalate, modified polyethylene terephthalate, and polyurethane.

3. The inorganic board material of the sandwich fiber mesh composite according to claim 1 or 2 further includes an adhesive, wherein the adhesive is sprayed onto the surface of the middle mesh; Optionally, the adhesive is selected from at least one of epoxy resin, phenolic resin, polyvinyl alcohol copolymer resin, polylactic acid ester, polyacrylate copolymer, polystyrene copolymer resin, modified polyurethane, polyacrylonitrile copolymer resin, polyvinyl acetate, and polyamide hot melt adhesive.

4. The inorganic board material with sandwich fiber mesh composite according to claim 1 or 2, wherein, The raw materials of the inorganic slurry, by weight, include: 50 to 85 parts of hemihydrate gypsum, 3 to 25 parts of silicate cement, 2 to 10 parts of waste paper pulp, 2 to 13 parts of filler, 0.5 to 3 parts of industrial starch, and 0.5 to 5 parts of additives. Optionally, the filler includes any one or more of lime, fly ash, and calcium carbonate; Optionally, the additives include any one or more of water-reducing agents, coagulation regulators, and foaming agents.

5. The inorganic board material with sandwich fiber mesh composite according to any one of claims 1 to 4, wherein, The mesh is a single-layer mesh with a mesh size between 2mm and 15mm; Optionally, the fiber diameter of the mesh is 0.2 mm to 2 mm.

6. The inorganic board material with sandwich fiber mesh composite according to any one of claims 1 to 5, wherein, The fiber diameter of the three-dimensional fiber web is 10 μm to 200 μm; Optionally, the average fiber spacing of the three-dimensional fiber web is 0.3 mm to 8 mm; Optionally, the thickness of the three-dimensional fiber web is 3 mm to 20 mm.

7. The sandwich fiber mesh composite inorganic board according to claim 4, wherein, The water-reducing agent is selected from any one or more of aliphatic water-reducing agents, polycarboxylate water-reducing agents, and naphthaleneethanesulfonic acid; The coagulation regulator is selected from any one or more of gypsum dihydrate, calcium chloride, volcanic ash, and sulfate. The foaming agent is selected from any one or more of sodium dodecyl sulfate, sodium fatty alcohol polyoxyethylene ether sulfate, sodium α-alkenyl sulfonate, and hydrogen peroxide.

8. The inorganic board material with sandwich fiber mesh composite according to claim 7, wherein, The water-reducing agent is selected from any one or more of potassium tartrate, acrylic acid and sodium acrylate, sulfonated styrene, isothiocyanate and naphthyl ethanesulfonic acid.

9. A method for preparing an inorganic board material with sandwich fiber mesh composite as described in any one of claims 1 to 8, comprising: 1) Grouting: The inorganic grout is injected and fills the pores of the sandwich fiber mesh to form the sandwich fiber mesh. An integral continuous phase in the inorganic slurry; 2) Slurry shaping: Compact the material obtained in step 1) and scrape off and recycle the excess inorganic slurry; 3) Surface paper lamination: The lower and upper surfaces of the compacted material in step 2) are bonded together with a surface paper. 4) Solidification, drying, cutting and packaging: The material in step 3) is solidified, dried, cut and packaged to obtain a high-strength three-dimensional fiber mesh reinforced, sandwich fiber mesh composite inorganic board.

10. The method according to claim 9, wherein, Step 1) includes: tractioning the sandwich fiber mesh into the grouting section, whereby the inorganic slurry is injected into the sandwich fiber mesh through a slurry pipe; Optionally, in the grouting section, the grout pipe is located above the sandwich fiber mesh; along the conveying direction of the sandwich fiber mesh, a first upper pressure roller is provided on the upper surface of the grouted material, and a vibration device and a first lower pressure roller are provided on the lower surface of the material. The inorganic grout is squeezed and vibrated sequentially into the pores of the upper three-dimensional fiber mesh, the middle mesh and the lower three-dimensional fiber mesh of the sandwich fiber mesh, forming an integral continuous phase in which the sandwich fiber mesh is embedded in the inorganic grout. Optionally, the vibration device is a vibrating belt, and the vibrating belt is provided with a transmission roller; Optionally, the vibration frequency of the vibration device is from 30 Hz to 200 Hz.

11. The method according to any one of claims 9 to 10, wherein, Step 2) includes: conveying the material from step 1) to the slurry shaping section for compaction; Optionally, in the slurry shaping section, the upper and lower surfaces of the material are respectively provided with a second upper pressure roller and a second lower pressure roller to fill the pores of the sandwich fiber web with the inorganic slurry and scrape off and recycle the excess inorganic slurry.

12. The method according to any one of claims 9 to 11, wherein, Step 3) includes: transferring the compacted material from step 2) to the surface paper composite section; Optionally, in the surface paper composite section, an upper paper roller and a lower paper roller are respectively provided on the upper and lower surfaces of the material, and surface paper released at the same speed by the upper paper roller and the lower paper roller is bonded and laminated to the upper and lower surfaces of the material respectively.

13. The method according to any one of claims 9 to 12, further comprising the step of preparing the sandwich fiber web, including: Polymer raw materials are melt-blown to form a three-dimensional fiber web; Apply adhesive to one side of the grille surface; The side of the mesh coated with adhesive contacts the three-dimensional fiber mesh, and the mesh is laid on the three-dimensional fiber mesh; Adhesive is sprayed onto the other side surface of the grille; The polymer raw material is continued to be melt-blown on the other side of the mesh that is coated with adhesive until a sandwich structure with three-dimensional fiber mesh-mesh-three-dimensional fiber mesh is formed; The sandwich structure is pressurized and cured until it is bonded together as a whole; Optionally, the polymer raw material is one or more polymers; Optionally, the curing temperature is between 110°C and 200°C.

14. The method according to claim 13, wherein, The meltblown includes: The polymer raw material is heated and melted in an extruder to form a melt; The molten material is sprayed out through a meltblown die to form fibers, and then blown and refined by a high-speed hot airflow from holes near the nozzle, and then collected onto a continuously operating take-up belt to form a three-dimensional fiber web with good resilience. Optionally, the temperature of the extruder is 260°C to 310°C; Optionally, the meltblown die head includes a plurality of nozzles, the diameter of which is from 0.05 mm to 1.2 mm; Optionally, the pressure of the meltblown die head is from 0.2 MPa to 1.2 MPa; Optionally, the temperature of the meltblown die is between 195°C and 265°C. Optionally, the wind pressure is 15 kMPa to 28 kMPa.

15. An inorganic board material with a sandwich fiber mesh composite, prepared by any one of claims 9 to 14.

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