Inorganic board compounded with nonwoven fiber web and preparation method therefor

Abstract

An inorganic board compounded with a nonwoven fiber web, and a preparation method therefor. The inorganic board compounded with a nonwoven fiber web comprises two layers of nonwoven fiber composite webs, and an inorganic slurry, the inorganic slurry filling honeycomb-like pores of the fiber webs of the upper and lower layers of the nonwoven fiber composite webs, and cured, to form the inorganic board compounded with a nonwoven fiber web. The inorganic board compounded with a nonwoven fiber web is characterized by high strength and high nail-holding capacity.

Description

Nonwoven fiber web composite inorganic board and method for manufacturing the same

[0001] The present application claims priority to the Chinese patent application No. CN202410865900.6, filed on June 28, 2024, and entitled "Nonwoven fiber web composite inorganic board and method for manufacturing the same", the content of which is incorporated herein by reference. TECHNICAL FIELD

[0002] The present application / present application embodiments relate to, but are not limited to, the field of building, and in particular to, but are not limited to, nonwoven fiber composite web, nonwoven fiber web composite inorganic board and methods for manufacturing the same. BACKGROUND

[0003] Gypsum board has a wide application in making green and environmentally friendly products as interior partition wall. However, the inner part of the surface paper of the existing gypsum board is fragile gypsum, which has poor impact resistance and nail holding capacity, causing inconvenience in hanging heavy objects on the surface of the gypsum board, insufficient strength as an indoor partition wall, and the need for vertical carrying during transportation to avoid breakage. Because the fibers are difficult to disperse and flow in the gypsum slurry, the effect of adding inorganic fibers into the gypsum slurry is very limited, and the toughness and strength of the gypsum board cannot be fundamentally solved. Similarly, although the glass mesh sinking into the core of the gypsum board or the glass cloth adhering to the surface of the gypsum board can improve the strength of the gypsum board to a certain extent, the performance improvement is still very limited because it is only the adhesion of layered glass fibers and gypsum.

[0004] Nonwoven fabric is a fabric that does not need to be formed by spinning and weaving. It is a porous honeycomb-like fiber web / fabric made by directional or random arrangement of short fibers or filaments through bonding or adhesion, etc. Common preparation methods include needle punching, thermal bonding and chemical bonding, etc. In recent years, the production technology of nonwoven materials has developed rapidly, and three-dimensional honeycomb structures can be obtained, which are widely used in medical and health care, carpets, cleaning materials, geotechnical construction, sound absorption and insulation, filtration and other fields. From nonwoven fabrics with nanoscale fiber diameter such as mask filter cloth and battery separator, to nonwoven fabrics with 10 microns to millimeter scale fiber diameter such as industrial scouring pad, seedling bed, sewage filtration net and industrial carpet, these nonwoven fabrics with three-dimensional honeycomb structure can be mass-produced.

[0005] SUMMARY

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

[0007] The first aspect of the present application provides a nonwoven fiber composite web having honeycomb pores, comprising a fiber web and a surface layer bonded to the fiber web.

[0008] The second aspect of the present application provides a method for preparing a nonwoven fiber composite web, comprising fiber web formation and bonding and solidification of the fiber web and the surface layer.

[0009] The third aspect of the present application provides a nonwoven fiber web composite inorganic board, comprising two nonwoven fiber composite webs and an inorganic slurry, wherein the fiber webs of the two nonwoven fiber composite webs are arranged oppositely and the inorganic slurry is filled into the honeycomb pores of the fiber webs of the upper and lower nonwoven fiber composite webs and solidified to form a nonwoven fiber web composite inorganic board.

[0010] The fourth aspect of the present application provides a method for preparing a nonwoven fiber web composite inorganic board, comprising lower nonwoven fiber composite web grouting, upper nonwoven fiber composite web grouting, composite shaping of the upper and lower grouted nonwoven fiber composite webs, solidification and drying, and cutting and packaging.

[0011] The fifth aspect of the present application provides a nonwoven fiber web composite inorganic board prepared by the above method.

[0012] Other aspects can become apparent after reading and understanding the accompanying drawings and detailed description.

[0013] SUMMARY

[0014] 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.

[0015] Fig. 1 is a structural schematic diagram of a nonwoven fiber web composite inorganic board of the present application;

[0016] Fig. 2 is a partial enlarged view of Fig. 1;

[0017] Fig. 3 is a structural schematic diagram of a nonwoven fiber web composite inorganic board of the present application;

[0018] Fig. 4 is a partial enlarged view of Fig. 3;

[0019] Fig. 5 is a schematic diagram of a production process of a nonwoven fiber web composite inorganic board of the present application;

[0020] Fig. 6 is a schematic diagram of another alternative production process of a nonwoven fiber web composite inorganic board of the present application.

[0021] Reference numerals: 1: surface layer; 2: fiber web; 3: first slurry pipe; 4: first upper pressing roller; 5: first vibrating device; 6: second slurry pipe; 7: second vibrating device; 8: deflection roller; 9: first transmission device; 10: second transmission device; 11: material blocking plate; 12: inorganic slurry.

[0022] Detailed description

[0023] Plant fibers can be biodegradable, and are excellent green and environment-friendly reinforcing materials. For example, bast fibers have the best strength among natural fibers, are widely available, and have low cost, and have outstanding advantages such as being renewable and biodegradable, and are an excellent choice for preparing biodegradable composite reinforcing materials. Selecting biodegradable natural plant fibers such as bast fibers, coconut shell fibers, and straw fibers, and using a non-woven method to make a three-dimensional honeycomb web, and making a composite material with gypsum, will effectively compensate for the above-mentioned defects of existing gypsum boards.

[0024] The present application makes a fiber web with honeycomb pores by a non-woven method using main fibers and a spray adhesive or main fibers and fusion fibers, and then bonds the fiber web with a surface layer using a hot melt adhesive to form a non-woven fiber composite web. The upper and lower two layers of non-woven fiber composite webs are injected into gypsum slurry, and the upper and lower two layers of non-woven fiber composite webs are bonded and combined into an integrated non-woven fiber web composite inorganic board material, obtaining a non-woven fiber web composite inorganic board material with high strength and high nail holding force characteristics.

[0025] The first aspect of the present application provides a non-woven fiber composite web having honeycomb pores, comprising a fiber web and a surface layer bonded to the fiber web.

[0026] In an exemplary embodiment, the fiber web has honeycomb pores.

[0027] In an exemplary embodiment, the thickness of the surface layer is 30 μm to 1500 μm, for example, 30 μm, 100 μm, 300 μm, 600 μm, 800 μm, 1000 μm, 1200 μm, 1400 μm, or 1500 μm, etc., but is not limited to the listed values, and other unlisted values within this range are also applicable.

[0028] In an exemplary embodiment, the surface layer can be selected from at least one of inorganic fibers, organic fibers, organic / inorganic fiber blended fabrics, non-woven porous fabrics, and papers made of plant fibers. The surface layer has good compatibility and affinity with the fiber web to facilitate bonding of the two layers into an integrated structure, and also imparts good sound insulation and thermal insulation properties to the gypsum board. In addition, the porosity and hydrophilicity of the surface layer impart excellent bonding and coating properties to the surface of the gypsum board.

[0029] In an exemplary embodiment, the nonwoven porous cloth is selected from at least one of chemical bonded nonwoven cloth, thermal bonded nonwoven cloth, needle punched nonwoven cloth, hydroentangled nonwoven cloth, melt blown nonwoven cloth, and spunbonded nonwoven cloth.

[0030] In an exemplary embodiment, the facing layer can be a nonwoven cloth composed of glass fibers and other fibers, wherein the other fibers are selected from at least one of rice straw fiber, hemp fiber, viscose fiber, polylactic acid fiber, PET fiber, and polyamide fiber.

[0031] Preferably, the thickness of the nonwoven cloth is 500 μm to 1500 μm, for example, 500 μm, 1000 μm, or 1500 μm, and the like, but is not limited to the listed values, and other values not listed within the range are also applicable.

[0032] In an exemplary embodiment, the facing layer can also be a facing paper used for conventional gypsum board.

[0033] In an exemplary embodiment, the fiber web is a three-dimensional network structure formed by randomly oriented base fibers bonded by a spray adhesive, or a three-dimensional network structure formed by randomly oriented base fibers and fusion fibers mixed and bonded.

[0034] In an exemplary embodiment, the thickness of the fiber web is 4 mm to 10 mm.

[0035] In an exemplary embodiment, the fiber web has three-dimensional irregular and interpenetrating honeycomb pores.

[0036] Preferably, the average fiber spacing of the fiber web is 1 mm to 10 mm.

[0037] In an exemplary embodiment, the base fibers are selected from any one or more of plant fibers, inorganic fibers, and petrochemical fibers.

[0038] Optionally, the petrochemical fibers are selected from any one or more of polyamide, polyurethane, and polyacetate.

[0039] Optionally, the inorganic fibers are selected from at least one of basalt fibers and glass fibers.

[0040] Optionally, the plant fibers are biodegradable natural plant fibers, and preferably, the plant fibers are selected from at least one of coconut shell fiber, coconut palm fiber, hemp fiber, wood fiber, bamboo fiber, straw fiber, rice straw fiber, and straw fiber.

[0041] Optionally, the hemp fibers are selected from at least one of flax, kenaf, jute, abroma, and apocynum.

[0042] Preferably, the diameter of the main fibers is 10 μm to 300 μm, for example, 30 μm to 60 μm, 40 μm to 90 μm, 40 μm to 140 μm, etc., but not limited to the listed values and ranges, and other subsets of values not listed within the range and unlisted values are equally applicable.

[0043] Preferably, the fiber length of the main fibers is 1 mm to 80 mm.

[0044] In an exemplary embodiment, the main fibers are formed by mixing two or more types of fibers to form a honeycomb network structure having a desired pore range and high resilience.

[0045] In an exemplary embodiment, the spray adhesive is a hot melt adhesive, and optionally, the spray adhesive is selected from at least one of polyether modified polyester hot melt adhesive, EVA hot melt adhesive, TPU hot melt adhesive, PES hot melt adhesive, maleic anhydride grafted polyethylene hot melt adhesive, PA hot melt adhesive, PO hot melt adhesive, polycaprolactone hot melt adhesive, and polyhydroxybutyrate-valerate hot melt adhesive.

[0046] In an exemplary embodiment, the polyhydroxybutyrate-valerate hot melt adhesive is a modified polyhydroxybutyrate-valerate hot melt adhesive.

[0047] In an exemplary embodiment, the melt fiber is selected from at least one of a modified polyethylene terephthalate (PET) copolymer fiber, a polybutylene terephthalate copolymer fiber, a maleic anhydride grafted polypropylene fiber, an o-phthalic anhydride grafted polyethylene fiber, a benzoic anhydride grafted ES fiber, a polyurethane fiber, a polyurethane elastomer fiber, a modified polyurethane fiber, and a modified polyamide fiber.

[0048] Optionally, the diameter of the melt fiber is 6 μm to 50 μm.

[0049] The second aspect of the present application provides a method for preparing a nonwoven fiber composite web, comprising: web forming and adhesive bonding and curing of the fiber web and the facing layer.

[0050] In an exemplary embodiment, in the fiber web forming step, the main fibers of the fiber web are bonded and fixed by the molten spray adhesive, which comprises: opening the main fibers, uniformly applying the spray adhesive to the surface of the main fibers, and blowing the web; and specifically, comprises:

[0051] The main fibers are fully opened into single fibers and fed into a spray pipe or slit, and the outlet of the spray pipe or slit is provided with an adhesive spray hole, the spray adhesive is sprayed from the adhesive spray hole and uniformly applied to the surface of the main fibers, and the main fibers uniformly coated with the spray adhesive are blown to the web former by the auxiliary air pipe at the outlet.

[0052] Preferably, the minimum spraying amount of the spray adhesive sprayed from the spraying hole in the method is an average surface density of 1 g / m 2 to 50.0 g / m 2 , for example, 5 g / m 2 , 10 g / m 2 , 20 g / m 2 , 30 g / m 2 , 40 g / m 2 , or 50 g / m 2 , etc., but not limited to the listed values, and other unlisted values within the range are also applicable.

[0053] In an exemplary embodiment, the bonding temperature of the spray adhesive is 110°C to 160°C, for example, 110°C, 120°C, 130°C, 140°C, 150°C, or 160°C, etc., but not limited to the listed values, and other unlisted values within the range are also applicable.

[0054] In an exemplary embodiment, in the fiber web forming step, the main fibers and the fusion fibers of the fiber web are bonded and fixed by fusion fiber lap bonding, which includes: separately opening and mixing the main fibers and the fusion fibers and blowing them to form a web; specifically, including:

[0055] The main fibers and the fusion fibers are separately opened into single fibers and mixed after being separated, and the mixed main fibers and the fusion fibers are sent to a spray pipe or a gap, and blown to a web former under the blowing of high-pressure hot air, and optionally, the web former can be matched with negative pressure air to assist web forming.

[0056] In an exemplary embodiment, the melting point of the fusion fiber is 115°C to 180°C, for example, 115°C, 120°C, 130°C, 140°C, 150°C, 160°C, 170°C, or 180°C, etc., but not limited to the listed values, and other unlisted values within the range are also applicable.

[0057] In an exemplary embodiment, the bonding, compounding, and curing of the fiber web and the surface layer include: dipping the hot melt adhesive on one side of the formed fiber web through a hot melt adhesive tank to bond, compound, and cure with the surface layer, becoming a non-woven fiber composite web;

[0058] Optionally, the hot melt adhesive is selected from at least one of polyether modified polyester hot melt adhesive, EVA hot melt adhesive, TPU hot melt adhesive, PES hot melt adhesive, maleic anhydride grafted polyethylene hot melt adhesive, PA hot melt adhesive, PO hot melt adhesive, polycaprolactone hot melt adhesive, and polyhydroxybutyrate-valerate hot melt adhesive.

[0059] In an exemplary embodiment, the polyether-modified polyester hot melt adhesive is a modified polyethylene terephthalate (PET) hot melt adhesive.

[0060] The third aspect of the present application provides a non-woven fiber mesh composite inorganic plate, comprising two non-woven fiber composite meshes and an inorganic slurry, wherein the fiber meshes of the two non-woven fiber composite meshes are arranged oppositely, and the inorganic slurry is filled in the honeycomb pores of the fiber meshes of the upper and lower non-woven fiber composite meshes, and after curing, a non-woven fiber mesh composite inorganic plate is formed.

[0061] In an exemplary embodiment, the inorganic slurry is a pumpable slurry with fluidity, which is prepared by mixing semi-hydrated gypsum and Portland cement with water.

[0062] In an exemplary embodiment, the raw materials of the inorganic slurry include, by weight, 65 to 90 parts of semi-hydrated gypsum, 3 to 13 parts of Portland cement, 1 to 6 parts of waste paper slurry, 1 to 6 parts of filler, 0.2 to 3 parts of industrial starch, and 0.5 to 4 parts of auxiliary agent.

[0063] Preferably, the semi-hydrated gypsum is, for example, 65, 70, 75, 80, 85, or 90 parts, but is not limited to the listed values, and other values not listed within this range are also applicable.

[0064] Preferably, the Portland cement is, for example, 3, 6, 9, 12, or 13 parts, but is not limited to the listed values, and other values not listed within this range are also applicable.

[0065] Preferably, the waste paper slurry is, for example, 1, 2, 3, 4, 5, or 6 parts, but is not limited to the listed values, and other values not listed within this range are also applicable.

[0066] Preferably, the filler is, for example, 1, 2, 3, 4, 5, or 6 parts, but is not limited to the listed values, and other values not listed within this range are also applicable.

[0067] Preferably, the industrial starch is, for example, 0.2, 0.5, 1.0, 1.5, 2.0, 2.5, or 3.0 parts, but is not limited to the listed values, and other values not listed within this range are also applicable.

[0068] Preferably, the auxiliary agent is, for example, 0.5, 1, 2, 3, or 4 parts, but is not limited to the listed values, and other values not listed within this range are also applicable.

[0069] In an exemplary embodiment, the filler includes at least one of lime and fly ash.

[0070] In an exemplary embodiment, the admixture comprises at least one of a water reducing agent, a setting regulator, a foaming agent.

[0071] In an exemplary embodiment, the water reducing agent is selected from any one or more of an aliphatic water reducing agent, a polycarboxylic acid water reducing agent, and a naphthalene sulfonate water reducing agent; preferably, selected from any one or more of potassium tartrate, acrylic acid and sodium acrylate, sulfonated styrene, isothiocyanate, naphthalene sulfonate.

[0072] In an exemplary embodiment, the setting regulator is selected from any one or more of dihydrate gypsum, calcium chloride, calcium carbonate, pozzolana, sulfate; optionally, the sulfate is calcium sulfate dihydrate.

[0073] In an exemplary embodiment, the foaming agent is selected from any one or more of sodium dodecyl sulfate, sodium fatty alcohol polyoxyethylene ether sulfate, sodium alpha-olefin sulfonate, hydrogen peroxide.

[0074] The fourth aspect of the present application provides a method for preparing a non-woven fiber mesh composite inorganic plate, comprising the following steps: injecting a lower layer of non-woven fiber mesh, injecting an upper layer of non-woven fiber mesh, shaping the lower and upper layers of non-woven fiber mesh, solidifying, drying, and cutting and packaging.

[0075] In an exemplary embodiment, the injecting a lower layer of non-woven fiber mesh comprises:

[0076] The face layer of the lower layer of non-woven fiber mesh is introduced into the lower layer injection section with the face layer facing down, and the inorganic slurry is injected into the interpenetrating honeycomb pores of the lower layer of non-woven fiber mesh on one side of the fiber mesh, and abuts against the face layer of the lower layer of non-woven fiber mesh, forming an integrated structure in which the lower layer of non-woven fiber mesh is embedded in the continuous phase of the inorganic slurry.

[0077] Optionally, in the lower layer injection section, a first slurry pipe and a first upper compression roller are sequentially arranged on one side of the fiber mesh of the lower layer of non-woven fiber mesh along the conveying direction, and a first vibration device is arranged at the bottom of the face layer of the lower layer of non-woven fiber mesh. After the inorganic slurry is injected through the first slurry pipe, the interpenetrating honeycomb pores of the lower layer of non-woven fiber mesh are filled and abutted against the face layer through the extrusion of the first upper compression roller and the vibration of the first vibration device.

[0078] Optionally, the vibration frequency of the first vibration device is 30 Hz to 200 Hz, for example, 30 Hz, 60 Hz, 90 Hz, 120 Hz, 150 Hz, 180 Hz, or 200 Hz, etc., but is not limited to the listed values, and other values not listed in this range are also applicable.

[0079] Optionally, the first vibrating device can be a first vibrating belt, and a transmission roller is arranged in the first vibrating belt to drive the first vibrating belt to vibrate.

[0080] In an exemplary embodiment, the upper-layer nonwoven fiber composite web grouting comprises:

[0081] The face layer of the upper-layer nonwoven fiber composite web is guided downward into the upper-layer grouting section, and the inorganic slurry is injected into the interpenetrating honeycomb pores of the upper-layer nonwoven fiber composite web on one side of the fiber web and abuts against the face layer of the upper-layer nonwoven fiber composite web, forming an integrated structure in which the upper-layer nonwoven fiber composite web is embedded in the continuous phase of the inorganic slurry; wherein the upper-layer grouting section is located above the lower-layer grouting section, the conveying direction of the upper-layer nonwoven fiber composite web is parallel and opposite to the conveying direction of the lower-layer nonwoven fiber composite web, and the conveying speed is the same;

[0082] Optionally, in the upper-layer grouting section, a second slurry pipe and a second upper compression roller are arranged in sequence along the conveying direction on one side of the fiber web of the upper-layer nonwoven fiber composite web, and a second vibrating device is arranged at the bottom of the face layer of the upper-layer nonwoven fiber composite web, the inorganic slurry is injected through the second slurry pipe, and the interpenetrating honeycomb pores of the upper-layer nonwoven fiber composite web are filled and abutted against the face layer through the extrusion of the second upper compression roller and the vibration of the second vibrating device;

[0083] Optionally, the vibration frequency of the second vibrating device is 30 Hz to 200 Hz, for example, 30 Hz, 60 Hz, 90 Hz, 120 Hz, 150 Hz, 180 Hz, or 200 Hz, etc., but is not limited to the listed values, and other unlisted values within this range are also applicable;

[0084] Optionally, the second vibrating device can be a second vibrating belt, and a transmission roller is arranged in the second vibrating belt to drive the second vibrating belt to vibrate.

[0085] In an exemplary embodiment, the nonwoven fiber composite web composite shaping of the upper-layer and lower-layer grouting comprises: after grouting, the conveying direction of the upper-layer nonwoven fiber composite web is turned by 180°, so that the fiber web of the upper-layer nonwoven fiber composite web is arranged opposite to the fiber web of the lower-layer nonwoven fiber composite web, and the conveying direction and speed are the same;

[0086] The turned upper-layer nonwoven fiber composite web and the lower-layer nonwoven fiber composite web are contacted and compacted, and the excess inorganic slurry is removed to be bonded into a continuous integrated structure in which the upper-layer and lower-layer nonwoven fiber composite webs are embedded in the inorganic slurry;

[0087] Optionally, a turning device is arranged at the bottom of the surface layer of the upper non-woven fiber composite web during the turning of the upper non-woven fiber composite web.

[0088] Optionally, the turning device is a turning roller.

[0089] Optionally, a material blocking plate is further arranged on one side of the fiber web of the upper non-woven fiber composite web during the turning of the upper non-woven fiber composite web, so as to fully prevent the inorganic slurry filled in the fiber web from flowing out.

[0090] In an exemplary embodiment, the solidification, drying and cutting package comprises: solidifying, drying and cutting the composite reshaped material to obtain the non-woven fiber web composite inorganic plate.

[0091] The fifth aspect of the present application provides a non-woven fiber web composite inorganic plate prepared by the above method.

[0092] The present application has the following technical effects:

[0093] The present application provides a non-woven fiber web composite inorganic plate, which is composed of an inorganic slurry filled in a non-woven fiber composite web having interpenetrating honeycomb-shaped pores, solving the problem that the comprehensive strength of a gypsum board obtained by adding chopped fibers to a conventional gypsum slurry is difficult to effectively improve.

[0094] 1) A non-woven fiber composite web is provided, which is composed of a honeycomb-shaped fiber web and a surface layer bonded to one side thereof. The honeycomb-shaped fiber web is formed by randomly oriented main fibers bonded by a spray adhesive or by randomly oriented main fibers and fusion fibers mixed and bonded to each other, having a three-dimensional net-like structure and three-dimensional random and interpenetrating pores;

[0095] 2) A high-flow inorganic slurry is filled and filled in the pores in the honeycomb-shaped fiber web to form a continuous phase, and the inorganic slurry fully maintains the strength of the inorganic plate after solidification;

[0096] 3) The outer side of the plate is the surface layer of the non-woven fiber composite web, which can be inorganic fiber, organic fiber, organic / inorganic fiber blended fabric, non-woven porous fabric, which can be directly obtained by surface spray dyeing treatment to obtain a decorative plate with a three-dimensional velvet effect, and has better sound insulation and heat preservation performance;

[0097] 4) The fibers are connected to form a three-dimensional net-like structure, which is integrated with the inorganic continuous phase, so that the comprehensive mechanical properties of the plate such as bending resistance, impact resistance and tensile strength are fundamentally improved, and the nailing force is increased by more than 1.5 times.

[0098] Other features and advantages of the present application will be set forth in the description that follows, and in part will be apparent from the description, or can be learned by practice of the application. The advantages of the present application will be realized and attained by the

[0099] The embodiments of the present application will be described in detail below. The embodiments and features in the embodiments of the present application can be combined with each other arbitrarily without conflict.

[0100] The present application will be further described in detail below with specific examples, but the examples should not be construed as limiting the present application.

[0101] The raw materials in the comparative examples and the embodiments of the present application are all market conventional products.

[0102] In the inorganic slurry in the embodiments 1 to 5, the proportions are shown in Table 1, wherein the components and weight ratio of the auxiliary agent in the embodiments 1 to 5 are:

[0103] Potassium tartrate: sulfonic acid styrene: isothiocyanate: dihydrate gypsum: calcium carbonate: volcanic ash: fatty alcohol polyoxyethylene ether sodium sulfate = 10:5:3:17:30:25:10.

[0104] Embodiment 1.

[0105] In the non-woven fiber composite net, the fiber net is formed by the lap joint and bonding of the main fibers and the fusion fibers, and the non-woven fiber composite net with interpenetrating honeycomb pores is produced:

[0106] The main fibers are jute fibers with a diameter of 25 μm to 80 μm and a length of 2.3 mm to 5.0 mm,

[0107] The fusion fibers are maleic anhydride grafted polypropylene fibers with a diameter of 15 μm to 40 μm and a length of 4 mm to 15 mm;

[0108] After the main fibers and the fusion fibers are separated into single fibers by being fully opened, they are respectively sent into the air jet gap through different pipes and blown to the net former under the blowing of hot air at a temperature of 135 ℃ to 145 ℃.

[0109] The specific thickness of the fiber net is 5.9 mm.

[0110] The surface layer is jute needle-punched non-woven fabric with a needle punching density of 400 pokes / cm 2 , a surface layer density of 100 g / m 2 , and a surface layer thickness of 0.6 mm to 0.9 mm.

[0111] The maleic anhydride grafted polyethylene hot melt adhesive is used to bond the surface layer and the honeycomb-shaped fiber net.

[0112] Referring to Figs. 1-2, the nonwoven fiber composite web comprises a fiber web 2 and a face layer 1 bonded to the fiber web 2, and the fiber web 2 has honeycomb-like pores.

[0113] Referring to Figs. 3-4, the nonwoven fiber web composite inorganic board comprises two nonwoven fiber composite webs and an inorganic slurry 12, wherein the fiber webs 2 of the two nonwoven fiber composite webs are arranged oppositely, and the inorganic slurry 12 is filled in the honeycomb-like pores of the fiber webs 2 of the upper and lower nonwoven fiber composite webs and is solidified to form a nonwoven fiber web composite inorganic board.

[0114] The method for preparing the nonwoven fiber web composite inorganic board comprises the following steps:

[0115] Lower nonwoven fiber composite web grouting: the face layer of the lower nonwoven fiber composite web is guided downward into a lower grouting section, and the inorganic slurry is injected into the interpenetrating honeycomb-like pores of the lower nonwoven fiber composite web on one side of the fiber web of the lower nonwoven fiber composite web and abuts against the face layer of the lower nonwoven fiber composite web to form an integrated structure in which the lower nonwoven fiber composite web is embedded in the continuous phase of the inorganic slurry; referring to Fig. 5, on the lower grouting section, a first slurry pipe 3 and a first upper pressing roller 4 are sequentially arranged on one side of the fiber web of the lower nonwoven fiber composite web along the conveying direction, and a first vibrating device 5 is arranged at the bottom of the face layer of the lower nonwoven fiber composite web, and after the inorganic slurry is injected through the first slurry pipe 3, the interpenetrating honeycomb-like pores of the lower nonwoven fiber composite web are filled and abut against the face layer through the extrusion of the first upper pressing roller 4 and the vibration of the first vibrating device 5, and here, the first vibrating device 5 is a first vibrating belt, and a transmission roller is arranged in the first vibrating device 5;

[0116] Upper layer nonwoven fiber composite web grouting: the face layer of the upper layer nonwoven fiber composite web is guided downward into the upper layer grouting section, and the inorganic slurry is injected into the interpenetrating honeycomb pores of the upper layer nonwoven fiber composite web on one side of the fiber web and is in contact with the face layer of the upper layer nonwoven fiber composite web, forming an integrated structure in which the upper layer nonwoven fiber composite web is embedded in the continuous phase of the inorganic slurry; see Figure 5, the upper layer grouting section is located above the lower layer grouting section, the conveying direction of the upper layer nonwoven fiber composite web is parallel and opposite to the conveying direction of the lower layer nonwoven fiber composite web, and the conveying speed is the same; in the upper layer grouting section, the second slurry pipe 6 and the second upper compression roller (not shown) are arranged in sequence on one side of the fiber web of the upper layer nonwoven fiber composite web along the conveying direction, the second vibration device 7 is arranged at the bottom of the face layer of the upper layer nonwoven fiber composite web, the inorganic slurry is injected through the second slurry pipe 6, and the interpenetrating honeycomb pores of the upper layer nonwoven fiber composite web are filled with the inorganic slurry through the extrusion of the second upper compression roller and the vibration of the second vibration device 7 and are in contact with the face layer; here, the second vibration device 7 is a second vibration belt, and a transmission roller is arranged in the second vibration device 7;

[0117] The composite shaping of the nonwoven fiber composite web grouted by the upper and lower layers includes: after grouting, the conveying direction of the upper layer nonwoven fiber composite web is turned by 180°, so that the fiber web of the upper layer nonwoven fiber composite web is arranged opposite to the fiber web of the lower layer nonwoven fiber composite web, and the conveying direction and speed are the same; the upper layer nonwoven fiber composite web and the lower layer nonwoven fiber composite web are contacted and compacted, so that the upper layer nonwoven fiber composite web and the lower layer nonwoven fiber composite web are filled with the inorganic slurry, then the excess inorganic slurry is removed and bonded to form a continuous integrated structure in which the upper and lower layer nonwoven fiber composite webs are embedded in the inorganic slurry; see Figure 5, during the turning process, a turning device is arranged at the bottom of the face layer of the upper layer nonwoven fiber composite web, and the turning device is a turning roller 8; see Figure 6, optionally, during the turning process, a material blocking plate 11 is further arranged on one side of the fiber web of the upper layer nonwoven fiber composite web; see Figures 5 to 6, during the compacting process, a first transmission device 9 and a second transmission device 10 are further arranged on the outer sides of the face layers of the upper layer nonwoven fiber composite web and the lower layer nonwoven fiber composite web respectively, for pulling and compacting the inorganic slurry;

[0118] Solidification, drying and cutting packaging includes: solidifying, drying and cutting packaging the material after composite shaping, to obtain an inorganic plate material compounded by nonwoven fiber web.

[0119] Example 2.

[0120] In the nonwoven fiber composite web, the fiber web with a thickness of 5.6 mm is formed by bonding and fixing the main fibers through the molten spray adhesive;

[0121] The main body fiber is poplar fiber, with a diameter of 10-20 μm and a length of 2-4.6 mm;

[0122] The spray adhesive is modified polyhydroxybutyric acid-valeric acid ester hot melt adhesive, with a bonding temperature of 130-140 °C, and the honeycomb-shaped fiber web is prepared.

[0123] The surface layer is made of modified poplar fiber and maleic anhydride grafted polystyrene short fiber, with a fiber diameter of 5-30 μm, a length of 3-15 cm, and a surface layer thickness of 0.5-1.0 mm.

[0124] The honeycomb-shaped fiber web and the surface layer are bonded and fixed by using modified polyethylene terephthalate hot melt adhesive.

[0125] The rest is the same as example 1.

[0126] Example 3.

[0127] In the non-woven fiber composite web, the fiber web with a thickness of 4.8 mm is formed by bonding and fixing the main body fiber and the fusion fiber, and a non-woven fiber composite web with interpenetrating honeycomb-shaped pores is produced:

[0128] The main body fiber of the fiber web is bamboo pulp fiber provided by Guangzhou Jinmu Paper Co., Ltd., with a diameter of 12-35 μm and a length of 1-3.6 mm,

[0129] The fusion fiber is benzoic anhydride grafted ES fiber, with a diameter of 6-18 μm and a length of 3-15 mm,

[0130] After the main body fiber and the fusion fiber are separated into single fibers by being fully opened, they are respectively sent into the air jet gap through different pipes, and are blown to the web former under the blowing of hot air at a temperature of 125-135 °C.

[0131] The surface layer is made of flame-retardant modified PET non-woven fabric, with a specification of 70 g / m2 and a surface layer thickness of 0.3-0.8 mm.

[0132] The rest is the same as example 1.

[0133] Example 4.

[0134] In the non-woven fiber composite web, the fiber web with a thickness of 5.8 mm is formed by bonding and fixing the main body fiber and the fusion fiber, and a non-woven fiber composite web with interpenetrating honeycomb-shaped pores is produced:

[0135] The main fibers of the fiber web are coconut shell fibers with a length of 2 cm to 4.5 cm and a diameter of 0.05 mm to 0.3 mm, and the fusion fibers are made of polybutylene terephthalate copolymer fibers to form a honeycomb fiber web;

[0136] The main fibers and the fusion fibers are separated into single fibers after being fully opened, and are respectively sent into the air jet gap through different pipes, and are blown to the web former under the blowing of hot air at a temperature of 135°C to 145°C.

[0137] The surface layer is made of a surface protection paper with a thickness of 0.5 mm to 0.8 mm.

[0138] The honeycomb-shaped fiber web is bonded and compounded with the surface protection paper by EVA hot melt glue.

[0139] The rest is the same as example 1.

[0140] Example 5.

[0141] In the non-woven fiber composite web, the fiber web with a thickness of 5.4 mm is formed by bonding and fixing the main fibers through the sprayed adhesive.

[0142] The main fibers of the fiber web are flax fibers with a diameter of 10 μm to 30 μm and a length of 1.3 mm to 3.8 mm,

[0143] The sprayed adhesive is polyether modified PET hot melt glue, and the bonding temperature is 140°C to 155°C to prepare a honeycomb-shaped fiber web.

[0144] The surface layer is made of a non-woven fabric produced by melt spinning of a blend of polyethylene succinate and polybutylene terephthalate, with a fiber diameter of 5 μm to 20 μm and a thickness of 0.3 mm to 0.7 mm after fusion by hydroentanglement.

[0145] The honeycomb-shaped fiber web and the surface layer are bonded and fixed by modified polyester hot melt glue.

[0146] The rest is the same as example 1.

[0147] Table 1. Inorganic slurry ratio table

[0148] Comparative example 1.

[0149] A commercially available ordinary gypsum board of Taishan brand with a thickness of 12 mm.

[0150] Comparative example 2.

[0151] The difference from example 1 is that the gypsum board is filled with 1.5 wt% glass fibers.

[0152] Test:

[0153] The inorganic board prepared in Example 1 to Example 5 and Comparative Example 1 to Comparative Example 2 was tested, and the thickness of all test samples was 12 mm, and the results are shown in Table 2.

[0154] Table 2. Performance of inorganic board

[0155] It has been proved that the inorganic board of the non-woven fiber web composite of the present application has the highest nail holding force increased by more than 1.5 times and the highest bending strength increased by more than 50% compared with the ordinary gypsum board, as shown in Table 2. The bending strength test adopts the American standard ASTM C473-17, and the nail holding force test adopts the standard GB / T 14018-2009.

[0156] Conclusion: The present application provides an inorganic board of non-woven fiber web composite, which is composed of an inorganic slurry filled in a non-woven fiber web with interpenetrating honeycomb-like pores, solving the problem that the comprehensive strength of the gypsum board obtained by adding chopped fibers in the conventional gypsum slurry is difficult to be effectively improved:

[0157] 1) A non-woven fiber composite web is provided, which is composed of a honeycomb-like fiber web and a surface layer bonded to one side thereof. The honeycomb-like fiber web is formed by randomly oriented main fibers bonded by a spray adhesive or by randomly oriented main fibers and fusion fibers mixed and bonded to each other, having a three-dimensional net-like structure and three-dimensional random and interpenetrating pores;

[0158] 2) The high-flow inorganic slurry is filled in the pores of the honeycomb-like fiber web to form a continuous phase, and after the inorganic slurry is solidified, the strength of the inorganic board is fully maintained;

[0159] 3) The outer side of the board is the surface layer of the non-woven fiber composite web, which can be inorganic fibers, organic fibers, organic / inorganic fiber blended fabrics, non-woven porous fabrics, which can be directly obtained as decorative boards with three-dimensional velvet effect after surface spray dyeing treatment, and has better sound insulation and heat preservation performance;

[0160] 4) The fibers are connected to form a three-dimensional net, which is integrated with the inorganic continuous phase, and the comprehensive mechanical properties of the board such as bending resistance, impact resistance and tensile strength are fundamentally improved, and the nail holding force is increased by more than 1.5 times.

[0161] 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. An inorganic board composed of nonwoven fiber webs, comprising two nonwoven fiber webs and an inorganic slurry, wherein the nonwoven fiber webs include fiber webs and a surface layer bonded to the fiber webs, the fiber webs having honeycomb-like pores, wherein... The two nonwoven fiber composite webs are arranged facing each other, and the inorganic slurry fills the honeycomb-like pores of the upper and lower layers of the nonwoven fiber composite webs, which are then cured to form an inorganic board composed of nonwoven fiber webs.

2. The inorganic board material composited with nonwoven fiber web according to claim 1, wherein, The surface layer is selected from at least one of inorganic fibers, organic fibers, organic / inorganic fiber blended fabrics, nonwoven porous fabrics, and paper made from plant fibers; The fiber web is a three-dimensional mesh structure formed by bonding randomly oriented main fibers with a spray adhesive, or a three-dimensional mesh structure formed by bonding randomly oriented main fibers with welded fibers. Optionally, the main fiber is selected from any one or more of plant fibers, inorganic fibers, and petrochemical fibers; Optionally, the welded fiber is selected from at least one of modified polyethylene terephthalate copolymer fiber, polybutylene terephthalate copolymer fiber, maleic anhydride grafted polypropylene fiber, phthalic anhydride grafted polyethylene fiber, benzoic anhydride grafted ES fiber, polyurethane fiber, polyurethane elastomer fiber, modified polyurethane fiber, and modified polyamide fiber.

3. The inorganic board material composited with nonwoven fiber web according to claim 1 or 2, wherein, The raw materials of the inorganic slurry, by weight, include: 65 to 90 parts of hemihydrate gypsum, 3 to 13 parts of silicate cement, 1 to 6 parts of waste paper pulp, 1 to 6 parts of filler, 0.2 to 3 parts of industrial starch, and 0.5 to 4 parts of additives. Optionally, the filler comprises at least one of lime and fly ash; Optionally, the additives include at least one of water-reducing agents, coagulation regulators, and foaming agents.

4. The inorganic board composited with nonwoven fiber web according to any one of claims 1 to 3, wherein, The thickness of the surface layer is from 30 μm to 1500 μm.

5. The inorganic board composited with nonwoven fiber web according to any one of claims 1 to 3, wherein, The surface layer is a nonwoven fabric composed of glass fiber and other fibers, wherein the other fibers are selected from at least one of straw fiber, hemp fiber, viscose fiber, polylactic acid fiber, PET fiber and polyamide fiber; Optionally, the thickness of the nonwoven fabric is from 500 μm to 1500 μm.

6. The inorganic board composited with nonwoven fiber web according to any one of claims 1 to 3, wherein, The thickness of the fiber web is 4 mm to 10 mm; Optionally, the average fiber spacing of the fiber web is 1 mm to 10 mm.

7. The inorganic board material composited with nonwoven fiber web according to claim 2, wherein, The petrochemical fiber is selected from any one or more of polyamide, polyurethane, and polyacetate; Optionally, the inorganic fiber is selected from at least one of basalt fiber and glass fiber; Optionally, the plant fiber is a biodegradable natural plant fiber. Preferably, the plant fiber is selected from at least one of coconut shell fiber, coconut palm fiber, hemp fiber, wood fiber, bamboo fiber, wheat straw fiber, rice straw fiber, and straw fiber. Optionally, the hemp fiber is selected from at least one of flax, kenaf, jute, yellow kenaf and Apocynum venetum; Optionally, the diameter of the main fiber is from 10 μm to 300 μm; Optionally, the fiber length of the main fiber is 1 mm to 80 mm.

8. The inorganic board material composited with nonwoven fiber web according to claim 2, wherein, The spray adhesive is a hot melt adhesive; Optionally, the spray adhesive is selected from at least one of polyether-modified polyester hot melt adhesive, EVA hot melt adhesive, TPU hot melt adhesive, PES hot melt adhesive, maleic anhydride-grafted polyethylene hot melt adhesive, PA hot melt adhesive, PO hot melt adhesive, polycaprolactone hot melt adhesive, and polyhydroxybutyrate-valerate hot melt adhesive.

9. The inorganic board composite with nonwoven fiber web according to claim 2, wherein, The diameter of the fusion-bonded fiber is 6 μm to 50 μm.

10. The inorganic board material composited with nonwoven fiber web according to claim 3, wherein, The water-reducing agent is selected from any one or more of aliphatic water-reducing agents, polycarboxylate water-reducing agents, and naphthalene ethanesulfonic acid water-reducing agents; preferably, the water-reducing agent is selected from any one or more of potassium tartrate, acrylic acid and sodium acrylate, sulfonated styrene, isothiocyanate, and naphthalene ethanesulfonic acid. Optionally, the coagulation regulator is selected from any one or more of gypsum dihydrate, calcium chloride, calcium carbonate, volcanic ash, and sulfate; Optionally, 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.

11. A method for preparing an inorganic board composite of nonwoven fiber web according to any one of claims 1 to 10, comprising: Grouting of the lower nonwoven fiber composite mesh: The lower nonwoven fiber composite mesh is introduced into the lower grouting section with its surface layer facing down. Inorganic slurry is injected into the interpenetrating honeycomb pores of the lower nonwoven fiber composite mesh on one side of the fiber mesh and abuts against the surface layer of the lower nonwoven fiber composite mesh, forming an integral structure in which the lower nonwoven fiber composite mesh is embedded in the continuous phase of the inorganic slurry. The upper nonwoven fiber composite mesh is injected with grout. The upper nonwoven fiber composite mesh is introduced into the upper grouting section with its surface layer facing down. Inorganic slurry is injected into one side of the fiber mesh of the upper nonwoven fiber composite mesh, filling the interconnected honeycomb-like pores of the upper nonwoven fiber composite mesh and abutting against the surface layer of the upper nonwoven fiber composite mesh, forming an integral structure in which the upper nonwoven fiber composite mesh is embedded in the continuous phase of inorganic slurry. The upper grouting section is located above the lower grouting section, and the conveying direction of the upper nonwoven fiber composite mesh is parallel to and opposite to the conveying direction of the lower nonwoven fiber composite mesh, with the same conveying speed. The upper and lower layers of nonwoven fiber composite mesh are composite shaped by grouting. After grouting, the conveying direction of the upper nonwoven fiber composite mesh is turned 180° so that the fiber web of the upper nonwoven fiber composite mesh faces the fiber web of the lower nonwoven fiber composite mesh, and the conveying direction and speed are the same. The turned upper nonwoven fiber composite mesh is then brought into contact with and compacted with the lower nonwoven fiber composite mesh. Excess inorganic slurry is removed and the mesh is bonded together to form a continuous and integral structure in which the upper and lower nonwoven fiber composite meshes are embedded in the inorganic slurry. Solidification, drying, cutting, and packaging: The composite-shaped material is solidified, dried, cut, and packaged to obtain an inorganic board material with a nonwoven fiber web composite.

12. The method according to claim 11, wherein, In the lower grouting section, a first slurry pipe and a first upper pressure roller are sequentially arranged on one side of the fiber web of the lower nonwoven fiber composite web along the conveying direction. A first vibration device is provided at the bottom of the surface layer of the lower nonwoven fiber composite web. After the inorganic slurry is injected through the first slurry pipe, it is squeezed by the first upper pressure roller and vibrated by the first vibration device, thus filling the interconnected honeycomb pores of the lower nonwoven fiber composite web and abutting against the surface layer. In the upper grouting section, a second grout pipe and a second upper pressure roller are sequentially arranged along the conveying direction on one side of the upper nonwoven fiber composite mesh. A second vibration device is provided at the bottom of the surface layer of the upper nonwoven fiber composite mesh. The slurry is injected through the second slurry pipe, squeezed by the second upper pressure roller and vibrated by the second vibration device, and injected into and fills the interconnected honeycomb pores of the upper nonwoven fiber composite network and abuts against the surface layer. Optionally, the first vibration device is a first vibration belt, and the second vibration device is a second vibration belt; the first vibration belt and the second vibration belt are respectively provided with drive rollers; Optionally, the vibration frequency of the first vibration device and the second vibration device is from 30 Hz to 200 Hz.

13. The method according to claim 11, wherein, During the turning process of the upper nonwoven fiber composite web, a turning device is provided at the bottom of the surface layer of the upper nonwoven fiber composite web; Optionally, the steering device is a steering roller; Optionally, a baffle plate is also provided on one side of the fiber web of the upper nonwoven fiber composite web.

14. The method according to any one of claims 11 to 13, further comprising a step of preparing a nonwoven fiber composite web, including: Fiber web formation and bonding and curing of fiber web with surface layer; In the fiber web forming step, the main fibers of the fiber web are bonded and fixed together by molten spray adhesive, or the main fibers of the fiber web are bonded and fixed together by fusion splicing fiber overlap.

15. The method according to claim 14, wherein, The bonding, bonding, and curing of the fiber web and the surface layer includes: dipping one side of the fiber web into hot melt adhesive in a hot melt adhesive tank and then bonding, bonding, and curing it with the surface layer to form a nonwoven fiber composite web. Optionally, the hot melt adhesive is selected from at least one of polyether-modified polyester hot melt adhesive, EVA hot melt adhesive, TPU hot melt adhesive, PES hot melt adhesive, maleic anhydride-grafted polyethylene hot melt adhesive, PA hot melt adhesive, PO hot melt adhesive, polycaprolactone hot melt adhesive, and polyhydroxybutyrate-valerate hot melt adhesive.

16. The method of claim 14, wherein, In the fiber web forming step, the main fibers of the fiber web are bonded and fixed together by molten spray adhesive, including: After the main fiber is fully opened into individual fibers and separated, it enters the nozzle or gap. At the same time, the outlet of the nozzle or gap is provided with a spray adhesive hole. The spray adhesive is sprayed out from the spray adhesive hole and evenly coated on the surface of the main fiber. The main fiber, which is evenly coated with the spray adhesive, is blown to the web forming machine through the auxiliary air duct outside the outlet to form a web. Optionally, the minimum amount of adhesive sprayed from the spray nozzle has an average areal density of 1 g / m³. 2 Up to 50.0g / m 2 ; Optionally, the bonding temperature of the spray adhesive is 110°C to 160°C.

17. The method of claim 14, wherein, In the fiber web forming step, the main fibers of the fiber web are bonded and fixed together by fusion splicing, including: After the main fiber and the welded fiber are fully opened into individual fibers and separated, they are mixed and opened. The mixed and opened main fiber and the welded fiber are sent into a nozzle or gap and blown into a web forming machine under high pressure hot air to form a web. Optionally, the melting point of the welded fiber is between 115°C and 180°C.

18. An inorganic board composed of a nonwoven fiber web, prepared by any one of claims 11 to 17.

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