1. A thistle board, includes board core and mask paper, the raw materials of board core include: gypsum clinker, expanded vermiculite, silica fume, phase change material, heat conduction reinforcing material, reinforcing fiber and polyvinyl alcohol;

the phase change material and the thermal conductivity enhancement material are located in the interlaminar spaces of the expanded vermiculite.

2. The paper-faced gypsum board of claim 1, wherein the raw materials of the board core further comprise one or more of a foaming agent, a starch, and a water reducing agent.

3. The paper-faced gypsum board of claim 2, wherein the weight ratio of the gypsum clinker, the thermal conductivity enhancing material, the reinforcing fibers, the expanded vermiculite, the silica fume, the phase change material, the polyvinyl alcohol, the water reducing agent, the foaming agent, and the starch is (90 to 100): 0.01 to 4): 0.1 to 4): 0.5 to 7): 0.5 to 6): 1 to 15: (0.3 to 3): 0 to 0.3): 0 to 0.05): 0.3 to 5;

preferably, the weight ratio of the gypsum clinker, the thermal conductivity enhancing material, the reinforcing fibers, the expanded vermiculite, the silica fume, the phase change material, the polyvinyl alcohol, the water reducing agent, and the foaming agent to the starch is (90 to 100): 0.01 to 4): 0.1 to 3): 0.5 to 5): 1 to 15): 0.3 to 3: (0.01 to 0.3): 0.01 to 0.05): 0.3 to 0.9.

4. The gypsum plasterboard of claim 3, wherein the exfoliated vermiculite is a 60 mesh screen exfoliated vermiculite;

optionally, the expanded vermiculite pore size distribution is from 0.01 μm to 50 μm;

optionally, the gypsum clinker has an average particle size of 80 mesh to 100 mesh;

optionally, the phase change material has a melting point of 20 ℃ to 50 ℃;

optionally, the average length of the thermal conductivity enhancing material is 10 μm to 100 μm; the average diameter of the heat conduction reinforcing material is 0.1nm to 1000nm, the preferred average length is 10 μm to 50 μm, and the preferred average diameter is 100nm to 600 nm;

optionally, the reinforcing fibers have an average length of 1mm to 10mm and an average diameter of 5 μm to 10 μm; more preferably, the reinforcing fibers have an average length of 1mm to 5mm and an average diameter of 5 μm to 10 μm.

5. The paper-faced gypsum board of any one of claims 1 through 4,

the phase change material is selected from any one or more of emulsified paraffin, polyethylene glycol and lauric acid; optionally, the polyethylene glycol has a melting point of 30 ℃ to 50 ℃ and a molecular weight of no greater than 2000; optionally, the paraffin wax has a melting point of 20 ℃ to 41 ℃;

optionally, the heat conduction reinforcing material is selected from any one or more of carbon network, silicon carbide nanowire, metal nanowire, carbon nanotube and graphene, preferably the heat conduction reinforcing material is silicon carbide heat conduction reinforcing material;

optionally, the reinforcing fiber is selected from any one or more of carbon fiber, pitch-based carbon fiber, polypropylene fiber, glass fiber, graphene carbon fiber and gypsum whisker, preferably, the reinforcing fiber is carbon fiber.

6. The gypsum plasterboard of any one of claims 2 to 4, wherein the polyvinyl alcohol is selected from polyvinyl alcohol PVA2488, polyvinyl alcohol PVA 1788;

optionally, the foaming agent is an anionic surfactant; preferably, the anionic surfactant is selected from basfGYP 3550、GYP 2680、SASN812 or 3110 or sodium lauryl sulfate;

optionally, the water reducing agent is selected from one or more of polycarboxylic acid water reducing agents, melamine resins, sulphonated polycondensate water reducing agents;

optionally, the starch is a pregelatinized starch, preferably, the viscosity range of the pregelatinized starch is: from 50 to 100 mPas.

7. A method of making a paper-faced gypsum board according to any one of claims 2 to 6, comprising:

a) dispersing the reinforced fibers in water, and adding the polyvinyl alcohol to obtain a mixture a;

b) uniformly mixing the expanded vermiculite with the mixture a and the foaming agent to obtain a mixture b;

c) uniformly mixing the gypsum clinker, the silica fume, the water reducing agent and the mixture b to obtain gypsum slurry, and drying the gypsum slurry to obtain a gypsum board core;

optionally, in the step a, the amount of water is the amount of water used for the standard consistency of the powder formed by uniformly mixing the gypsum clinker, the silica fume, the expanded vermiculite, the polyvinyl alcohol and the water reducing agent.

8. The method of making a paper-faced gypsum board according to claim 7, wherein the exfoliated vermiculite is treated as follows:

I) uniformly mixing the expanded vermiculite with supersaturated salt water to obtain a mixture c;

II) heating the mixture c to above 100 ℃, and then cooling to below 0 ℃ until the particle size d50 of the expanded vermiculite is less than or equal to 0.45 mu m; optionally, the warming and cooling cycles are more than two times;

III) filtering the mixture c treated in the step II) by using filter paper, washing by using deionized water, drying the obtained solid to obtain treated expanded vermiculite, uniformly mixing the heat conduction reinforcing material, the phase change material and the treated expanded vermiculite, and standing for 1d to 3d at room temperature to obtain a mixture d;

IV) storing the mixture d for 5min to 40min under the conditions of constant temperature and constant pressure;

v) separating the mixture d treated in step IV) to obtain the treated expanded vermiculite.

9. The method of making a paper-faced gypsum board of claim 8, wherein the ratio of the amount of exfoliated vermiculite to the amount of supersaturated brine in step I is from 2g to 50g of exfoliated vermiculite per liter of supersaturated brine; the salt is an alkali metal salt; preferably, the alkali metal salt comprises a sodium salt or a lithium salt.

10. The method for preparing a gypsum plasterboard according to claim 8 or 9, wherein the temperature rise in step II is 100-200 ℃, and the temperature rise time is 4-12 h; optionally, the temperature of the temperature reduction is 0 ℃ to-30 ℃;

optionally, in step IV, the constant temperature is 35 ℃ to 45 ℃ and the constant pressure is-0.09 MPa to 0.01 MPa.

Background

As is well known, gypsum is a porous building material, and gypsum board has excellent properties of light weight, fire resistance, flame retardance and the like, and is a common building decoration material and an indoor partition board. However, conventional paper-faced gypsum board (9.5mm, 12mm) has certain limitations in thermal insulation performance. The heat preservation performance of the gypsum board is improved in the northern area with cold weather, and the gypsum board has important significance for saving energy and improving the comfort of human living environment.

The phase-change gypsum board can cause the mechanical strength of the base plate to be reduced to a certain degree due to the doping of the phase-change material, and meanwhile, the phase-change material in the core of the phase-change gypsum board is easy to leak, so that the application of the phase-change gypsum board is severely limited.

Disclosure of Invention

The following is a summary of the subject matter described in detail herein. This summary is not intended to limit the scope of the present application.

The application solves the problems through a new process, and prepares the functional gypsum board with good performance. The thickness of the gypsum board substrate is 9.5mm to 12 mm.

The application provides a thistle board, including board core and mask paper, the raw materials of board core include: gypsum clinker, expanded vermiculite, silica fume, phase change material, heat conduction reinforcing material, reinforcing fiber and polyvinyl alcohol;

the phase change material and the thermal conductivity enhancement material are located in the interlaminar spaces of the expanded vermiculite.

In one embodiment, the board core raw material further comprises one or more of a foaming agent, starch and a water reducing agent.

In one embodiment, the weight ratio of the gypsum clinker, the thermal conductivity enhancing material, the reinforcing fibers, the expanded vermiculite, the silica fume, the phase change material, the polyvinyl alcohol, the water reducing agent, the foaming agent, and the starch is (90 to 100): 0.01 to 4): 0.1 to 4): 0.5 to 7): 0.5 to 6): 1 to 15): 0.3 to 3): 0 to 0.3): 0 to 0.05): 0.3 to 5;

in one embodiment, the weight ratio of the gypsum clinker, the thermal conductivity enhancing material, the reinforcing fibers, the expanded vermiculite, the silica fume, the phase change material, the polyvinyl alcohol, the water reducing agent, and the foaming agent to the starch is (90 to 100): (0.01 to 4): (0.1 to 3): (0.5 to 5): (1 to 15): (0.3 to 3): (0.01 to 0.3): (0.01 to 0.05): (0.3 to 0.9).

In one embodiment, the exfoliated vermiculite is 60 mesh screen exfoliated vermiculite;

in one embodiment, the expanded vermiculite pore size distribution is from 0.01 μm to 50 μm;

in one embodiment, the gypsum clinker has an average particle size of 80 mesh to 100 mesh;

in one embodiment, the phase change material has a melting point of 20 ℃ to 50 ℃;

in one embodiment, the thermally conductive reinforcing material has an average length of 10 μm to 100 μm; the average diameter of the heat conduction reinforcing material is 0.1nm to 1000nm, the preferred average length is 10 μm to 50 μm, and the preferred average diameter is 100nm to 600 nm;

in one embodiment, the reinforcing fibers have an average length of 1mm to 10mm and an average diameter of 5 μm to 10 μm; more preferably, the reinforcing fibers have an average length of 1mm to 5mm and an average diameter of 5 μm to 10 μm.

In one embodiment, the phase change material is selected from any one or more of emulsified paraffin, polyethylene glycol, and lauric acid; optionally, the polyethylene glycol has a melting point of 30 ℃ to 50 ℃ and a molecular weight of no greater than 2000; optionally, the paraffin wax has a melting point of 20 ℃ to 41 ℃;

in one embodiment, the thermal conductivity enhancing material is selected from any one or more of carbon network, silicon carbide nanowire, metal nanowire, carbon nanotube and graphene, preferably the thermal conductivity enhancing material is silicon carbide thermal conductivity enhancing material;

in one embodiment, the reinforcing fiber is selected from any one or more of carbon fiber, pitch-based carbon fiber, polypropylene fiber, glass fiber, graphene carbon fiber, and gypsum whisker, preferably, the reinforcing fiber is carbon fiber.

In one embodiment, the polyvinyl alcohol is selected from polyvinyl alcohol PVA2488, polyvinyl alcohol PVA 1788;

in one embodiment, the foaming agent is an anionic surfactant; preferably, the anionic surfactant is selected from basfGYP 3550、GYP 2680、SASN812 or 3110 or sodium lauryl sulfate;

in one embodiment, the water reducing agent is selected from one or more of polycarboxylic acid based water reducing agents, melamine resins, sulphonated polycondensate water reducing agents;

in one embodiment, the starch is a pregelatinized starch, preferably having a viscosity in the range of: 50 to 100 mPas (1# rotor).

In another aspect, the present application provides a method for preparing the above paper-surface gypsum board, comprising:

a) dispersing the reinforced fibers in water, and adding the polyvinyl alcohol to obtain a mixture a;

b) uniformly mixing the expanded vermiculite with the mixture a and the foaming agent to obtain a mixture b;

c) uniformly mixing the gypsum clinker, the silica fume, the water reducing agent and the mixture b to obtain gypsum slurry, and drying the gypsum slurry to obtain a gypsum board core;

in one embodiment, in step a, the amount of water used is the amount of water used for the standard consistency of the powder after the gypsum clinker, the silica fume, the expanded vermiculite, the polyvinyl alcohol and the water reducing agent are uniformly mixed.

In one embodiment, the exfoliated vermiculite is treated as follows:

I) uniformly mixing the expanded vermiculite with supersaturated salt water to obtain a mixture c;

II) heating the mixture c to above 100 ℃, and then cooling to below 0 ℃ until the particle size d50 of the expanded vermiculite is less than or equal to 0.45 mu m; optionally, the warming and cooling cycles are more than two times;

III) filtering the mixture c treated in the step II) by using filter paper, washing by using deionized water, drying the obtained solid to obtain treated expanded vermiculite, uniformly mixing the heat conduction reinforcing material, the phase change material and the treated expanded vermiculite, and standing for 1d to 3d at room temperature to obtain a mixture d;

IV) storing the mixture d for 5min to 40min under the conditions of constant temperature and constant pressure;

v) separating the mixture d treated in step IV) to obtain the treated expanded vermiculite.

In one embodiment, the ratio of the amount of exfoliated vermiculite to the supersaturated brine in step I is from 2g to 50g of exfoliated vermiculite per litre of supersaturated brine; the salt is an alkali metal salt; preferably, the alkali metal salt comprises a sodium salt or a lithium salt.

In one embodiment, the temperature of the temperature rise in step II is 100-200 ℃, and the temperature rise time is 4-12 h; optionally, the temperature of the temperature reduction is 0 ℃ to-30 ℃;

in one embodiment, in step IV, the constant temperature is 35 ℃ to 45 ℃ and the constant pressure is-0.09 MPa to 0.01 MPa.

The application widens the application range and functions of the gypsum board. The concrete advantages are as follows:

the phase-change material in the gypsum base material is effectively prevented from leaking, the high-temperature resistance of the gypsum board is improved, the mechanical property is not reduced due to the addition of the phase-change material, and the gypsum board has excellent mechanical property and thermal insulation property;

additional features and advantages of the application will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the application. Other advantages of the present application may be realized and attained by the invention in its aspects as described in the specification.

Drawings

The accompanying drawings are included to provide an understanding of the present disclosure and are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and together with the examples serve to explain the principles of the disclosure and not to limit the disclosure.

FIGS. 1A, 1B and 1C show the expanded vermiculite sheets prepared in example 1 of the present application, as seen from the graph, the pore size distribution of the treated expanded vermiculite is about 0.01 μm to about 50 μm.

Detailed Description

In order to make the objects, technical solutions and advantages of the present application more apparent, embodiments of the present application are described in detail below. It should be noted that the embodiments and features of the embodiments in the present application may be arbitrarily combined with each other without conflict.

Example 1

In this example, the water reducing agent was a polycarboxylic acid water reducing agent, available from basf corporation,pce541f.f; polyvinyl alcohol was purchased from clony international trade, shanghai ltd, PVA 2488; the foaming agent is purchased from Pasteur Limited company, is an anionic surfactant,GYP 2680. The silica fume is purchased from the Angn China company, 200 plus 1000 meshes; the reinforced fiber is carbon fiber, the average length is 3mm, and the average diameter is 7 μm; the phase-change material is emulsified paraffin, and the phase-change temperature is 20-41 ℃; the average length of the silicon carbide nanowire heat conduction reinforcing material is 10-50 mu m, and the average diameter is 100-600 nm; the expanded vermiculite is from Hubei Lingshou county; the starch was pregelatinized starch with a viscosity of 55mpa.s (1# rotor).

The treatment method of the expanded vermiculite comprises the following steps:

(1) crushing vermiculite to prepare expanded vermiculite with high expansion rate (screening by a 60-mesh sieve), cleaning the expanded vermiculite with deionized water, and mixing with NaCl supersaturated solution (the weight of the vermiculite is 20g/L) to obtain a mixed solution of the expanded vermiculite and water;

(2) placing the mixed solution of the expanded vermiculite and the water prepared in the step (1) on an electric heater (160 ℃), heating while stirring (periodically supplementing deionized water), cooling to room temperature after 8 hours, then gradually cooling to-10 ℃, optionally placing on an electric heating plate again after 8 hours, and repeatedly circulating for many times until the particle size d50 of the expanded vermiculite is less than or equal to 0.45 um;

(3) filtering the vermiculite mixture prepared in the step (2) by using filter paper, and washing the vermiculite by using deionized water;

(4) the vermiculite on the filter paper is placed in an oven to dry until ready for use, at which time the expanded vermiculite has a pore size distribution of about 0.01 μm to 50 μm.

The following is the gypsum board manufacturing process:

uniformly dispersing 1g of the silicon carbide nanowire heat conduction reinforcing material in 20g of emulsified paraffin (the phase change melting point is 20-41 ℃), fully and uniformly mixing expanded vermiculite nanosheets (vermiculite on the filter paper dried in the step (4)) with the emulsified paraffin, standing for 1d at room temperature, and then maintaining for 20 minutes under the conditions of constant temperature (the temperature is 40 +/-2 ℃) and constant pressure (the vacuum degree is-0.09 MPa-0.01 MPa); under the action of capillary force and surface tension, the emulsified paraffin is immersed into the pores of the expanded vermiculite. The expanded vermiculite was then transferred to filter paper and the surface of the expanded vermiculite was freed from the seeping emulsified paraffin in a drying oven above the melting point of the phase change material (60 ℃). The filter paper was continuously replaced until no evidence of leakage was observed.

And weighing mixing water according to the water consumption of the standard consistency (the water consumption of the standard consistency is tested by uniformly mixing 1000g of desulfurized gypsum clinker, 10g of silica fume, 20g of expanded vermiculite nanosheet phase change material, 1g of polyvinyl alcohol, 6g of starch, 0.5g of water reducing agent and 3g of carbon fiber). Adding 3g of carbon fiber into water, uniformly dispersing, adding 1g of polyvinyl alcohol, and uniformly stirring; and then pouring the prepared expanded vermiculite nano sheet into the mixed solution, and uniformly stirring. Then, 0.2g of the blowing agent was added. And finally pouring 1000g of desulfurized gypsum clinker (sieved by a sieve of 80 meshes), 10g of silica fume, 0.5g of water reducing agent and 6g of starch into the solution, uniformly stirring to prepare gypsum slurry, lapping and bonding the gypsum slurry and a protective paper to form a wet gypsum board with paper surface, drying (baking for 0.5h at 160 ℃, baking for 1h at 110 ℃, and then drying to constant weight at 45 ℃) to obtain the wet gypsum board with paper surface.

Example 2

The difference from the embodiment 1 is that the phase change material encapsulated in the expanded vermiculite nano-sheet is polyethylene glycol, the melting point of the polyethylene glycol is 30-50 ℃, and the molecular weight is not more than 2000; the amount of polyethylene glycol used was the same as the amount of phase change material used in example 1.

Example 3

The difference from example 1 is that the amount of silica fume added in the formulation was 20 g.

Example 4

The difference from example 1 is that the amount of carbon fibers added in the formulation is 1 g.

Example 5

The difference from example 1 is that the amount of exfoliated vermiculite added in the formulation is different. In the process of preparing the gypsum board, the addition amount of the expanded vermiculite nano-sheet is 10 g.

Comparative example 1

The difference between the comparative example and the example 1 is that the raw material of the paper-surface gypsum board does not relate to an expanded vermiculite phase-change material (in particular, the expanded vermiculite, the emulsified paraffin and the silicon carbide nanowire heat conduction reinforcing material which are left on the filter paper after the expanded vermiculite is treated in the step (4) of the example 1).

Comparative example 2

This comparative example differs from example 1 in that emulsified paraffin and silicon carbide nanowire thermal conductivity enhancing materials are not involved.

Comparative example 3

This comparative example differs from example 1 in that no silicon carbide nanowire thermal conductivity enhancing material is involved.

Comparative example 4

This comparative example differs from example 1 in that no emulsified paraffin is involved.

Comparative example 5

This comparative example differs from example 1 in that, instead of expanded vermiculite, silicon carbide nanowires and emulsified paraffin are added during the process of making gypsum board.

Performance testing

1. And (3) testing the fracture load of the plate: the gypsum boards prepared in the examples and comparative examples were tested for breaking load according to the method of the chinese national standard GB/T9775-2008, and the results are shown in table 1.

TABLE 1 mechanical Properties of the products obtained in the examples and comparative examples

2. And (3) testing the fire resistance stability: the fire stability of the gypsum boards prepared in the examples and the comparative examples is tested according to the method of Chinese national standard GB/T9775-2008 'gypsum plasterboard', the fire stability of the examples is basically the same as that of the comparative examples, and the fire stability of some examples is even better than that of the comparative examples.

3. The gypsum boards prepared in the examples of the application and the comparative examples 1, 2 and 4 have no phase-change material leakage, but the comparative examples 1, 2 and 4 have no effect of reducing the indoor temperature fluctuation (according to the conventional test method in the field); comparative examples 3 and 5 have an effect of reducing the fluctuation of the indoor temperature to some extent, but the phase change material has a serious leakage and cannot be used for a long time.

4. Compared with the existing common paper-surface gypsum board, the paper-surface gypsum board prepared by the embodiment of the application also has the performance of reducing indoor noise.

Although the embodiments disclosed in the present application are described above, the descriptions are only for the convenience of understanding the present application, and are not intended to limit the present application. It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the disclosure as defined by the appended claims.