CN111734046A - Foamed ceramic composite panel and its preparation method and building wall panel - Google Patents

Abstract

The application provides a foamed ceramic composite board, which comprises a substrate, a first foamed ceramic layer and a second foamed ceramic layer, wherein the first foamed ceramic layer and the second foamed ceramic layer are arranged on two sides of the substrate; the thickness of the foamed ceramic composite plate is 100-300 mm. The foamed ceramic composite board has the advantages of stable structure, light weight, good heat preservation, flame retardance and waterproof performance, and can effectively solve the problems that the existing wall material is poor in heat preservation, flame retardance and waterproof performance, and is easy to crack, peel and fall off. The application also provides a preparation method of the foamed ceramic composite board and a wallboard for a building.

Description

Foamed ceramic composite panel and its preparation method and building wall panel

technical field

The present application relates to the technical field of building decoration materials, in particular to a foamed ceramic composite panel, a preparation method thereof, and a building wall panel.

Background technique

With the rapid development of the construction industry, the country has higher and higher requirements for environmental protection, energy saving, thermal insulation, heat insulation and waterproofing of construction and housing projects. For traditional building exterior walls, the walls are mostly made of bricks or concrete, and the exterior walls need to be insulated. At present, most of the thermal insulation treatment adopts processes such as fixing and hanging slurry with thermal insulation boards. The thermal insulation, flame retardant and waterproof performance are poor, and the existing thermal insulation boards are also prone to cracking, peeling and falling off. Especially for high-rise and super-high-rise exterior walls, the thermal insulation treatment of exterior walls is difficult to construct and the quality is difficult to control. Secondly, water seepage, wall cracking, peeling and falling off frequently occur in the inner walls of traditional buildings, which directly affect the quality of life of residents.

SUMMARY OF THE INVENTION

In view of this, the present application provides a foamed ceramic composite panel, a preparation method thereof, and a building wall panel. The invention effectively solves the problems that the existing wall insulation boards have poor thermal insulation, flame retardant and waterproof performance, and are prone to cracking, peeling and falling off.

In a first aspect, the present application provides a foamed ceramic composite plate, comprising a substrate and a first foamed ceramic layer and a second foamed ceramic layer disposed on both sides of the substrate; the thickness of the foamed ceramic composite plate 100-300mm.

Wherein, the first foamed ceramic layer, the substrate and the second foamed ceramic layer are stacked in sequence. The substrate refers to a substrate having a certain strength.

In the embodiment of the present application, the thickness ratio of the first foamed ceramic layer, the substrate and the second foamed ceramic layer is (1-2):(2-9):(1-2).

In the embodiment of the present application, the bulk density of the substrate is 300-1000 kg/m ³ ; the material of the substrate includes one or more of thermal insulation materials and construction waste scraps.

In the embodiment of the present application, one end side of the base plate is provided with a tenon, and the other end side of the base plate is provided with a tenon groove, and the tenon is matched with the tenon groove.

In the embodiment of the present application, the bulk densities of the first foamed ceramic layer and the second foamed ceramic layer are respectively 300-1000 kg/m ³ , and the resistance of the first foamed ceramic layer and the second foamed ceramic layer is The compressive strength is greater than or equal to 4MPa, respectively.

In the embodiment of the present application, the base plate is further provided with a plurality of reinforcing ribs, and the plurality of reinforcing ribs form a grid structure.

In the embodiment of the present application, the foamed ceramic composite plate further includes at least one through hole along the length direction of the foamed ceramic composite plate.

In a second aspect, the application also provides a method for preparing a foamed ceramic composite panel, comprising the following steps:

preparing a first foamed ceramic layer and a second foamed ceramic layer;

The first foamed ceramic layer and the second foamed ceramic layer are fixed on a carrier board facing each other at intervals, and the fixing board is encapsulated to form a mold with an opening facing the carrier board, and the mold is provided with an accommodation space ;

Filling the substrate raw material slurry into the accommodating space, after curing, a substrate is formed, and the substrate is arranged between the first foamed ceramic layer and the second foamed ceramic layer;

removing the bearing plate and the fixing plate, and cutting to obtain a foamed ceramic composite plate with a preset shape;

Wherein, the thickness of the foamed ceramic composite plate is 100-300mm.

In a third aspect, the present application further provides a building wall panel, comprising the foamed ceramic composite panel according to the first aspect of claim or the foamed ceramic composite panel obtained by the preparation method of the second aspect.

In the embodiment of the present application, the building wall panel further includes a decorative layer disposed on one side or both sides of the foamed ceramic composite panel, and the decorative layer includes an interface agent layer, a flexible putty layer and a color paint layer one or more of.

The beneficial effects of this application include:

(1) The foamed ceramic composite panel described in this application is stable in structure, light in weight, has good thermal insulation, flame retardant and waterproof properties, and can effectively prevent problems such as cracking, peeling and falling off during use; the foamed ceramic composite panel The panels also have outstanding sound insulation.

(2) The preparation method of the foamed ceramic composite plate described in the present application has the advantages of simple operation, high production efficiency and high yield, low cost, and can be used for large-scale industrial production, and the prepared foamed ceramic composite plate has excellent properties .

(3) The building wall panel described in the present application, the foamed ceramic composite panel includes a foamed ceramic composite panel, and the building wall panel can be used for both exterior wall panels and interior wall panels. The building wall panel is stable in structure, light in weight, has good thermal insulation, flame retardant, waterproof performance, and high compressive strength, so the building wall panel can be directly used as the main substrate of the wall, without being laid on the brick wall. Or cement wall method; reduce material waste, save environmental protection, and greatly reduce the difficulty of construction.

The advantages of the present application will be set forth in part in the following description, and in part will be obvious from the description, or may be learned by the practice of the embodiments of the present application.

Description of drawings

In order to illustrate the content of the present application more clearly, the following detailed description is given in conjunction with the accompanying drawings and specific embodiments.

FIG. 1 is a schematic structural diagram of a foamed ceramic composite panel 100 provided by an embodiment of the application;

2 is a cross-sectional view of a foamed ceramic composite plate along the A-A direction provided by an embodiment of the application;

3 is a cross-sectional view of a foamed ceramic composite plate along the A-A direction provided by another embodiment of the application;

4 is a cross-sectional view of a foamed ceramic composite plate along the A-A direction provided by another embodiment of the application;

5 is a cross-sectional view of a foamed ceramic composite plate along the A-A direction provided by another embodiment of the application;

FIG. 6 is a schematic structural diagram of a building wall panel 200 provided by another embodiment of the present application;

7 is a process flow diagram of a method for preparing a foamed ceramic composite panel provided by an embodiment of the application;

8 is a schematic top-view structure diagram of a mold in a method for preparing a foamed ceramic composite panel provided by an embodiment of the application;

FIG. 9 is a schematic structural diagram of a process flow of a method for preparing a foamed ceramic composite panel provided by another embodiment of the present application.

Detailed ways

The following are preferred implementations of the embodiments of the present application. It should be pointed out that for those skilled in the art, without departing from the principles of the embodiments of the present application, several improvements and modifications can be made. These improvements and modification are also regarded as the protection scope of the embodiments of the present application.

The embodiments of the present application will be further described below in terms of multiple embodiments. The embodiments of the present application are not limited to the following specific embodiments. Within the scope of the unchanged main rights, changes can be appropriately implemented.

Unless otherwise specified, the raw materials and other chemical reagents used in the examples of this application are all commercially available commodities.

As shown in FIG. 1 and FIG. 2, an embodiment of the present application provides a foamed ceramic composite panel 100, which includes a first foamed ceramic layer 10, a substrate 20 and a second foamed ceramic layer 30 that are stacked in sequence; The thickness of the foamed ceramic composite board 100 is 100-300 mm. The first foamed ceramic layer 10 and the second foamed ceramic layer 30 are respectively disposed on both sides of the substrate 20 .

In the embodiment of the present application, the thickness of the foamed ceramic composite plate 100 refers to the thickness along the Z-axis direction in FIG. 1 , and the thickness of the foamed ceramic composite plate 100 is the thickness of the first foamed ceramic layer 10 , the substrate 20 and the The sum of the three thicknesses of the second foamed ceramic layer 30 .

Optionally, the thickness of the foamed ceramic composite board 100 is 120-300 mm. Further, optionally, the thickness of the foamed ceramic composite plate 100 is -120-250 mm. For example, the thickness of the foamed ceramic composite plate 100 may be, but not limited to, 120 mm, 150 mm, 180 mm, 200 mm or 250 mm.

Optionally, the thickness ratio of the first foamed ceramic layer, the substrate and the second foamed ceramic layer is (1-2):(2-9):(1-2). Further, optionally, the thickness ratio of the first foamed ceramic layer, the substrate and the second foamed ceramic layer is (1.5-2):(4-5):(1.5-2).

In the embodiment of the present application, the thicknesses of the first foamed ceramic layer and the second foamed ceramic layer may be the same or different. In one embodiment, the thickness of the substrate is 60-200 mm. Alternatively, the thickness of the substrate is 90-200 mm. Alternatively, the thickness of the substrate is 90-120 mm. Optionally, the thickness of the first foamed ceramic layer is 10-80 mm. Alternatively, the thickness of the first foamed ceramic layer is 30-60 mm. Optionally, the thickness of the second foamed ceramic layer is 20-80mm. Alternatively, the thickness of the second foamed ceramic layer is 35-70 mm.

In the embodiment of the present application, referring to FIG. 3 , one end side of the base plate 20 is provided with a tenon 201 , and the other end side of the base plate 20 is provided with a tenon groove 202 , and the tenon is matched with the tenon groove. The tenon 201 and the tenon groove 202 are also the tenon and tenon groove of the foamed ceramic composite board. A plurality of the foamed ceramic composite panels are spliced through the tenon 201 and the tenon 202 . A plurality of the foamed ceramic composite plates can be spliced on the XY plane.

In the embodiment of the present application, one side surface 11 of the first foamed ceramic layer 10 close to the substrate 20 has a first texture, and one side surface 31 of the second foamed ceramic layer 30 close to the substrate 20 has a first texture The second texture, the first texture and the second texture respectively comprise protrusions, grooves, lines or other shapes. The shape and size of the first texture and the second texture may be the same or different. The bonding strength between the first foamed ceramic layer containing the first texture or the second foamed ceramic layer containing the second texture and the substrate is stronger, which can further improve the structural stability of the foamed ceramic composite board.

In the embodiment of the present application, the bulk densities of the first foamed ceramic layer and the second foamed ceramic layer are respectively 300-1000 kg/m ³ . Optionally, the bulk densities of the first foamed ceramic layer and the second foamed ceramic layer are respectively 400-900 kg/m ³ . In one embodiment, the bulk density of the first foamed ceramic layer is 400-600 kg/m ³ ; the bulk density of the second foamed ceramic layer is 500-900 kg/m ³ . The bulk density of the first foamed ceramic layer and the second foamed ceramic layer may be the same or different. For example, the bulk density of the first foamed ceramic layer is greater than the bulk density of the second foamed ceramic layer.

Optionally, the compressive strengths of the first foamed ceramic layer and the second foamed ceramic layer are respectively greater than or equal to 4 MPa. Optionally, the compressive strengths of the first foamed ceramic layer and the second foamed ceramic layer are respectively 5-15 MPa. Further, optionally, the compressive strengths of the first foamed ceramic layer and the second foamed ceramic layer are respectively 8-12 MPa. Both sides of the foamed ceramic composite plate of the present application are made of foamed ceramic materials with excellent compressive strength. Therefore, the foamed ceramic composite plate has outstanding overall compressive strength, impact resistance and long service life. Optionally, the compressive strength of the foamed ceramic composite board is greater than 3.5 MPa.

In the embodiment of the present application, the foamed ceramic composite board has outstanding thermal insulation performance. Optionally, the heat transfer coefficient of the foamed ceramic composite plate is 0.3-0.8 W/m ² ·K. Further, optionally, the heat transfer coefficient of the foamed ceramic composite plate is 0.5-0.6 W/m ² ·K. For example, the heat transfer coefficient of the foamed ceramic composite plate is 0.4W/m ² ·K, 0.45W/m ² ·K, 0.5W/m ² ·K, 0.55W/m ² ·K or 0.6W/m ² ·K.

In the embodiment of the present application, the bulk density of the substrate is 300-1000 kg/m ³ . Optionally, the bulk density of the substrate is 450-680 kg/m ³ . Optionally, the compressive strength of the substrate is 3-10 MPa. The material of the substrate includes one or more of thermal insulation materials and construction waste scraps. In one embodiment, the material of the substrate is a heat insulating material. In another embodiment, the material of the substrate is construction waste debris.

Optionally, the thermal insulation material includes one or more of polystyrene particles, vitrified microbeads, foamed cement, fibrous materials, porous materials and expanded perlite. Wherein, the fiber material includes one or more of mineral wool board, rock wool board, rock wool tape and glass wool; the porous material includes polystyrene foam, rigid polyurethane foam, phenolic board, calcium plastic and one or more of foam glass. The construction waste and scraps refer to the materials after the construction waste is harmless and crushed; wherein, the construction waste may include, but is not limited to, waste concrete, waste bricks, waste mortar pieces, waste sand or other waste construction materials . Optionally, the material of the substrate further includes an inorganic gel material, and the inorganic gel material includes one or more of cement, gypsum and lime. The inorganic gel material wraps the thermal insulation material, and the substrate is obtained after molding. The inorganic gel material can play a binding role, greatly improving the compressive strength of the substrate. For example, the substrate may be a thermal insulation board or a construction waste cast board.

In one embodiment, the thermal insulation material is composed of polystyrene particles and foamed cement, and the volume ratio of the polystyrene particles to the foamed cement is (5-8):(2-5). Optionally, the foamed cement is composed of cement mortar and a foaming agent; the foaming size of the foaming agent is controlled within 1 mm. For example, the volume ratio of the polystyrene particles to the foamed cement mortar is 7:3.

In the embodiment of the present application, the substrate is formed between the first foamed ceramic layer and the second foamed ceramic layer by casting. Since the surfaces of the first foamed ceramic layer and the second foamed ceramic layer have a cut wave pattern or sawtooth structure and there are a large number of semi-opened surfaces, the specific surface area is twice that of the ordinary plane. A more stable and firm bond can be achieved between the foamed ceramic layer and the second foamed ceramic layer.

In the embodiment of the present application, referring to FIG. 4 , a plurality of reinforcing ribs 203 are further provided in the base plate 20 , and the plurality of reinforcing ribs 203 form a grid structure. The reinforcing ribs 203 can further enhance the strength of the substrate, thereby helping to improve the strength of the foamed ceramic composite panel. The grid structure is adjusted based on the specific dimensions and contours of the substrate. The material of the reinforcing rib can be metal or hard polymer.

In the embodiment of the present application, referring to FIG. 5 , the foamed ceramic composite plate further includes at least one through hole 204 along the length direction of the foamed ceramic composite plate. The central axis of the through hole 204 is parallel to the first foamed ceramic layer 10 or the second foamed ceramic layer 30 ; the opening of the through hole 204 is formed on the side surface of the substrate 20 . On the one hand, the through holes of the foamed ceramic composite plate can enhance the effects of sound insulation and heat preservation, and on the other hand, the hollow through holes can give the thermal insulation matrix a larger space for strength adjustment. Since the first foamed ceramic layer and the second foamed ceramic layer have good water resistance and strong water permeability, the substrate has a long hydration time and a slow increase in strength. Strength of. In addition, the through holes can also be used as wiring conduits; especially when the foamed ceramic composite panel is used for interior wall panels.

Optionally, the diameter of the through hole 204 is 30-60 mm. Further, optionally, the diameter of the through hole 204 is 40-50 mm. For example, the diameter of the through hole 204 is specifically 30, 35, 40, 50 or 60 mm. Optionally, the distance between two adjacent through holes is 10-40mm. Optionally, the distance between two adjacent through holes is 20-30mm. Optionally, the total cross-sectional area of the at least one through hole accounts for 3-40% of the cross-sectional area of the substrate.

In the embodiment of the present application, the cross-sectional shape of the foamed ceramic composite plate along the XY plane may be, but not limited to, a rectangle, a rhombus, a regular hexagon, a triangle, a circle, a semicircle or a trapezoid. The cross-sectional shape of the foamed ceramic composite plate along the XY plane may also be other polygons, for example, other polygons with the number of sides greater than or equal to 5. The length and width of the foamed ceramic composite board can be adjusted based on actual needs, for example, the length and width of the foamed ceramic composite board is at least 200*100mm.

Referring to FIG. 6 , in an embodiment of the present application, a building wall panel 200 is further provided, and the building wall panel 200 includes a foamed ceramic composite panel 210 . The building wall panel 200 further includes a decorative layer 220 disposed on one side or both sides of the foamed ceramic composite panel 200 . The decoration layer 220 includes one or more of an interface agent layer 221 , a flexible putty layer 222 and a color paint layer 223 .

Since traditional external wall insulation boards rarely have the characteristics of self-insulation, self-waterproof, light weight and high strength at the same time, and they are prone to cracking, peeling and falling off after being laid on the external wall, there are still difficult construction problems for high-rise buildings. question. However, the building wall panel described in the present application has a first foamed ceramic layer and a second foamed ceramic layer on both sides of the base plate, which can have stable structure, light weight, heat preservation, flame retardant and waterproof performance at the same time; The building wall panel also has the characteristics of sound insulation and small deformation coefficient, and the building wall panel greatly improves the traditional external wall insulation board, which has a large deformation coefficient, is easy to age, is easy to fall off, and has poor thermal insulation, flame retardant and waterproof effects. The building wall panel can also save a lot of resources and reduce environmental pollution.

In addition, the traditional thermal insulation treatment on the outer wall often goes through multiple tedious processes to achieve thermal insulation treatment on the wall; the multiple tedious processes roughly include: (1) cleaning the wall, spraying the wall; (2) brushing at least one Plain cement slurry (5% building glue mixed with water); (3) Cement mortar leveling; (4) Coating special adhesive; (5) Laying rock wool board (hydrophobic type); (6) Adding and fixing galvanized Steel wire mesh; (7) A layer of M15 anti-cracking polymer mortar; (8) Spray exterior wall paint, one bottom and two degrees; a flexible water-resistant putty layer is provided. The treatment of the inner wall also needs to go through: (a) cleaning the wall and setting the interface agent layer; (b) setting the mixed mortar bonding layer (covered with alkali-resistant mesh cloth); (c) setting the mixed mortar surface layer ; (d) Set up a flexible water-resistant putty layer, interior wall paint (such as latex paint), one bottom and two sides, etc. The construction wall panel described in the present application can be either an outer wall or an inner wall. The construction wall panel can directly replace the traditional brickwork wall, and the decorative layer in the construction wall panel is only an interface agent. One or more of the layer, flexible putty layer and color coating layer, the construction is simple, and the construction cost is greatly saved, and it is more environmentally friendly; on the one hand, it has excellent performance, and on the other hand, it can prevent potential safety hazards.

Referring to FIG. 7, an embodiment of the present application further provides a preparation method of a foamed ceramic composite panel, comprising the following steps:

S10, prepare the first foamed ceramic layer and the second foamed ceramic layer;

S20, the first foamed ceramic layer and the second foamed ceramic layer are fixed on a carrier board facing each other at intervals, and the fixing board is packaged to form a mold with an opening facing the carrier board, and the mold is provided with a containment space;

S30, filling the substrate raw material slurry into the accommodation space, and after curing, a substrate is formed, and the substrate is disposed between the first foamed ceramic layer and the second foamed ceramic layer;

S40 , removing the bearing plate and the fixing plate, and cutting to obtain a foamed ceramic composite plate with a preset shape; wherein, the thickness of the foamed ceramic composite plate is 100-300 mm.

Optionally, in the S10, the first foamed ceramic layer and the second foamed ceramic layer may be prepared by, but not limited to, existing foamed ceramic preparation processes. For example, the embryonic body of the foamed ceramic is prepared from the raw material of the embryonic body, and after being sintered at a high temperature, the first foamed ceramic layer or the second foamed ceramic layer is obtained by cutting. The green body raw material includes tailings, talc, kaolin calcium oxide, dispersant and foaming agent. The dispersant may be, but is not limited to, a ceramic dispersant, such as one or more of sodium polyphosphate, sodium silicate, and sodium carbonate. The foaming agent may be, but is not limited to, one or more of silicon carbide, coke powder, coal powder and limestone. In the embodiment of the present application, the first foamed ceramic layer or the second foamed ceramic layer is a foamed ceramic material, which has the characteristics of low thermal conductivity, light weight, high hardness, corrosion resistance, wear resistance, water seepage resistance and easy regeneration. and other excellent performance.

Optionally, in the high temperature sintering process, the sintering temperature is 1130-1200° C., and the sintering time is 8-12 hours. The foamed ceramics with different bulk densities can be prepared by adjusting the dosage of the fluxing agent and the foaming agent in the preparation process of the foamed ceramics, thereby preparing the first foamed ceramic layer and the second foamed ceramic layer.

Optionally, in S20, the mold is as shown in FIG. 8, wherein the mold 300 includes a carrier plate 330, a first foamed ceramic layer 310 and a second foamed ceramic layer 320 fixed on the carrier plate 330, and the fixing plate 340; wherein, the first foamed ceramic layer 310 and the second foamed ceramic layer 320 are arranged opposite to each other, and the first foamed ceramic layer 310, the second foamed ceramic layer 320 and the fixing plate 340 are connected end to end , and together with the carrier plate 330 to form a receiving space 350 with an opening facing upward. The accommodating space of the mold 300 is used to fill the substrate raw material slurry.

Optionally, in the step S30, the substrate formed after curing has high bonding strength with the first foamed ceramic layer or the second foamed ceramic layer, and is not easy to fall off.

Optionally, before filling the substrate raw material slurry, a number of reinforcing ribs may be arranged in the receiving space, but not limited to, and according to the surrounding contour of the receiving space, the reinforcing ribs are built into a grid shape, and then filled. After entering the substrate raw material slurry, a substrate with reinforcing ribs inside can be obtained.

Optionally, before filling the substrate raw material slurry, at least one hollow tube may be provided in the receiving space, but is not limited to, and then the substrate raw material slurry is filled. After curing, the hollow tube is pulled out to obtain A substrate including at least one through hole along its length.

Optionally, the material of the substrate includes one or more of thermal insulation materials and construction waste scraps. In one embodiment, the material of the substrate is a heat insulating material. Wherein, the thermal insulation material includes one or more of polyphenylene particles, vitrified microbeads, foamed cement, fiber material, porous material and expanded perlite. Wherein, the fiber material includes one or more of mineral wool board, rock wool board, rock wool tape and glass wool; the porous material includes polystyrene foam, rigid polyurethane foam, phenolic board, calcium plastic and one or more of foam glass. The construction waste and scraps refer to the materials after the construction waste is harmless and crushed; wherein, the construction waste may include, but is not limited to, waste concrete, waste bricks, waste mortar pieces, waste sand or other waste construction materials . Optionally, the material of the substrate further includes an inorganic gel material, and the inorganic gel material includes one or more of cement, gypsum and lime. The inorganic gel material wraps the thermal insulation material, and the substrate is obtained after molding.

In one embodiment, the thermal insulation material is composed of polystyrene particles and foamed cement, and the volume ratio of the polystyrene particles to the foamed cement is (5-8):(2-5).

Optionally, by adjusting the shape or size of the fixing plate, tenons and tenon grooves can be formed on both sides of the final substrate. Wherein, the tenon and tenon groove can also be obtained by post-processing the prepared foamed ceramic composite plate.

In the embodiment of the present application, the use of construction waste scraps for forming the substrate can further save costs, which is beneficial to environmental protection and energy conservation.

The preparation methods described in the embodiments of the present application can be used to prepare the foamed ceramic composite panels described in the foregoing embodiments. Wherein, the specific limitation of the foamed ceramic composite plate is the same as the description of the foamed ceramic composite plate above, which is not repeated in this embodiment.

Another embodiment of the present application also provides a method for preparing a foamed ceramic composite panel, comprising the following steps:

S201, preparing a plurality of foamed ceramic blocks, and arranging the plurality of foamed ceramic blocks on a carrier plate at intervals in sequence;

S202 , adjusting the distance between two adjacent foamed ceramic blocks, and encapsulating a fixing plate to form a second receiving plate with an opening facing the carrying plate between two adjacent foamed ceramic blocks space;

S203 , filling the second accommodating space with a substrate raw material slurry, and after curing, a substrate is formed, and the substrate is disposed between two adjacent foamed ceramic blocks;

S204, removing the bearing plate and the fixing plate, cutting the foamed ceramic blocks to obtain a plurality of foamed ceramic composite panels, wherein each of the foamed ceramic blocks is divided into two foamed ceramic blocks after being cut The first foamed ceramic layer or the second foamed ceramic layer of the ceramic composite plate; wherein, the thickness of the foamed ceramic composite plate is 100-300 mm.

In the embodiment of the present application, FIG. 9 is a schematic structural diagram of the process flow of the preparation method, wherein in FIG. 9 (1) a plurality of foamed ceramic blocks 401 are arranged at intervals on the carrier plate 330 in sequence, and two adjacent foamed ceramic blocks The 401 is also fixed by the fixing plate 340 to form the second receiving space 402 . After adding the substrate raw material slurry to 402, the substrate 403 is formed after curing. Then, the foamed ceramic block 401 is cut along the dotted line in (2) in FIG. 9 to obtain a first foamed ceramic layer 404 and a second foamed ceramic layer 405, as shown in (3) in FIG. 9 . Here, the first foamed ceramic layer 404 and the second foamed ceramic layer 405 obtained by cutting a foamed ceramic block 401 are respectively used to manufacture two foamed ceramic composite panels.

Others in the preparation method are limited to be consistent with the description of the above preparation method, and are not repeated in this embodiment.

Below, according to the preparation method, several examples are listed to further illustrate the embodiments of the present application.

Example 1

A preparation method of a foamed ceramic composite panel, comprising the following steps:

Prepare and use a foamed ceramic plate with a bulk density of 450 kg/m ³ and a compressive strength of 8.2 MPa, with a thickness of about 45 mm, and after cutting, a first foamed ceramic layer and a second foamed ceramic layer are formed;

A mold is prepared and filled with substrate stock slurry. Among them, the substrate raw material slurry is 70% of the volume of polystyrene particles, with a diameter of less than 10mm, and 30% of the volume of foamed cement, wherein the foaming size of the foaming agent is controlled within 1mm. Depending on the amount of foaming, a substrate with a bulk density of about 550 kg/m ³ is obtained, sandwiched between the first foamed ceramic layer and the second foamed ceramic layer, and the thickness of the substrate is about 110 mm.

After removing the mold and cutting, a foamed ceramic composite plate is obtained, and the thickness of the foamed ceramic composite plate is about 200 mm. The heat transfer coefficient, compressive strength, flame retardant and sound insulation properties of the prepared foamed ceramic composite panels were tested, referring to the requirements of the GB-T23451-2009 standard. The results show that the heat transfer coefficient of the foamed ceramic composite board is 0.55W/m ² ·K, the compressive strength is 4.0MPa, the combustion performance reaches the A1 standard, the fire resistance limit is greater than 3h, and the air sound insulation is 46dB. The foamed ceramic composite board has the characteristics of self-heat preservation, self-waterproof, light weight and high strength, and good sound insulation effect; and the building wall boards made of the foamed ceramic composite board can be used for inner and outer wall boards respectively.

The above-mentioned embodiments only represent several embodiments of the present application, and the descriptions thereof are relatively specific and detailed, but should not be construed as a limitation on the scope of the patent of the present application. It should be pointed out that for those skilled in the art, without departing from the concept of the present application, several modifications and improvements can be made, which all belong to the protection scope of the present application. Therefore, the scope of protection of the patent of the present application shall be subject to the appended claims.

Claims (10)

1. The foamed ceramic composite board is characterized by comprising a substrate, a first foamed ceramic layer and a second foamed ceramic layer, wherein the first foamed ceramic layer and the second foamed ceramic layer are arranged on two sides of the substrate; the thickness of the foamed ceramic composite plate is 100-300 mm.

2. The foamed ceramic composite panel according to claim 1, wherein the thickness ratio of the first foamed ceramic layer, the substrate and the second foamed ceramic layer is (1-2): (2-9): (1-2).

3. The foamed ceramic composite panel according to claim 1, wherein the substrate has a bulk density of 300-1000kg/m³(ii) a The base plate is made of one or more of heat insulation materials and construction waste crushed materials.

4. The foamed ceramic composite board according to claim 1, wherein the base board has a tenon formed on one side surface thereof and a mortise formed on the other side surface thereof, and the tenon is matched with the mortise.

5. The foamed ceramic composite panel according to claim 1, wherein the first foamed ceramic layer and the second foamed ceramic layer have a bulk density of 300-1000kg/m, respectively³And the compressive strength of the first foamed ceramic layer and the compressive strength of the second foamed ceramic layer are respectively greater than or equal to 4 MPa.

6. The foamed ceramic composite panel according to claim 1, wherein a plurality of ribs are further provided in the base plate, and the plurality of ribs form a lattice structure.

7. The foamed ceramic composite panel of claim 1 or 6, further comprising at least one through-hole running the length of the foamed ceramic composite panel.

8. The preparation method of the foamed ceramic composite board is characterized by comprising the following steps of:

preparing a first foamed ceramic layer and a second foamed ceramic layer;

fixing the first foamed ceramic layer and the second foamed ceramic layer on a bearing plate at opposite intervals, packaging the fixing plate to form a die with an opening opposite to the bearing plate, wherein the die is provided with an accommodating space;

filling substrate raw material slurry into the accommodating space, and forming a substrate after curing, wherein the substrate is arranged between the first foamed ceramic layer and the second foamed ceramic layer;

removing the bearing plate and the fixing plate to obtain a foamed ceramic composite plate with a preset shape;

wherein, the thickness of the foamed ceramic composite plate is 100-300 mm.

9. A wallboard for construction comprising the foamed ceramic composite board according to any one of claims 1 to 7 or the foamed ceramic composite board obtained by the method according to claim 8.

10. The architectural wallboard of claim 9, further comprising a decorative layer disposed on one or both surfaces of the foamed ceramic composite panel, the decorative layer comprising one or more of an interfacial agent layer, a flexible putty layer, and a color paint layer.

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