三聚氰胺-脲醛树脂改性木基石膏复合材料的效果及机理

    Effect and mechanism of modification of particle-gypsum composites with melamine-urea-formaldehyde resin

    • 摘要: 为提高木基石膏复合材料的力学性能,以杉木刨花为增强相,以建筑石膏为连续相,采用三聚氰胺-脲醛树脂(melamine-urea-formaldehyde MUF)粘结初步成型和增湿固化 2阶段的免加石膏缓凝剂制备方法,开展了 MUF用量和木材/石膏质量比对木基石膏复合材料物理力学性能影响试验,并与相应产品标准、结构板材标准及现有文献进行对比。结果表明,试验范围内,MUF用量与木基石膏复合材料力学性能呈正相关关系,木材/石膏质量比的影响较小;MUF用量为15%以上时,木基石膏复合材料的力学性能满足《石膏刨花板:LY/T 1598-2011》产品标准的要求;MUF用量为21%及以上时,除顺纹抗弯强度,其余性能符合《定向刨花板:LY/T 1580-2010》结构板材标准的规定;MUF用量为33%及以上时,木基石膏复合材料达到《结构胶合板:GB/T 35216-2017》结构板材标准中E5.0~F16.0强度等级。抗弯性能试验中,石膏板为脆性破坏,木基石膏刨花板具有一定的延性性能。综合强度和成本,MUF用量为33%、木材/石膏质量比为0.30为较优的原材料配比。优化原材料配比条件下,木基石膏复合材料的内结合强度、静曲强度、弹性模量、位移延性系数和24 h吸水厚度膨胀率分别为1.28 MPa、16.5 MPa、7 350 MPa、1.64和1.23%。采用该2阶段制备方法,木基石膏复合材料中石膏晶体形态细长,且随着MUF用量的增加,晶体交错搭接、叠合现象明显,接触面积增加,晶体结构更加致密,石膏连续相强度增加;MUF用量提高,石膏在刨花表面的覆盖量明显增加,刨花增强相与石膏连续相之间界面性能显著改善。研究结果可为木基石膏复合材料力学性能的进一步提升提供参考,并为其产品的工程应用提供数据支撑。

       

      Abstract: Abstract:The mechanical properties of gypsum board was poor, and cannot be used as load-bearing material in construction.Plant fibers can be employed as the reinforcement to increase the mechanical properties of the gypsum board, but theimprovement increment on the mechanical properties was limited because of the addition of gypsum retarders during thepreparation of general particle-gypsum composites. The gypsum retarder solution deteriorated the morphology of gypsumcrystals, and the gypsum crystals became shorter and wider, and then the overlapping area decreased among them. The generalparticle-gypsum composites still cannot be used in structural application. In order to increase the mechanical properties of theparticle-gypsum composite, a two-step preparation process including pre-forming molding and moisture-curing was proposedin this study. The particle-gypsum composites with different melamine-urea-formaldehyde (MUF) content and the particle /gypsum ratio was prepared, and the physical and mechanical properties was tested. The effects of MUF content and theparticle / gypsum mass ratio on mechanical properties of the particle-gypsum composites were analyzed by one-factorexperiment. The results in the present study were compared with the requirements in three product standards and that in thereported literatures. The test results showed there was a positive relationship between the MUF content and the mechanicalproperties of the particle-gypsum composites, and the particle / gypsum mass ratio had a slight impact. The mechanicalproperties of the particle-gypsum composites with more than 15% MUF content met the requirements of standard LY/T 1598(2011), and the values, except longitudinal modulus of rupture, were in accordance with the requirements of standard LY/T1580 (2010) when MUF content was above 21%. The mechanical properties of the particle-gypsum composites reached E5.0-F16.0 grade according to the standard GB / T 35216 (2017), when 33% and higher MUF content was used. The curves ofbending load with deformation of gypsum boards exhibited linear elastic behavior due to the brittleness of gypsum crystals.All particle-gypsum composites in bending tests exhibited obvious non-linear behavior before the maximum load was reached,and the failure was ductile. The strengths of the composites in the present study were all higher than that in the reportedliteratures. Therefore, the particle-gypsum composites can be used as structural boards in construction. Based on thecombination of mechanical properties and costs, the performance of the particle-gypsum composites with 33% MUF contentand a particle/gypsum mass ratio of 0.30 were better, and the internal bond strength, modulus of rupture, modulus of elasticity,displacement ductility coefficient and 24 h thickness swelling of the particle-gypsum composite were 1.28 MPa, 16.5 MPa,7350 MPa, 1.64 and 1.23%, respectively. After the new preparation process was employed, the mechanical properties of theparticle-gypsum composites were increased greatly due to the increase of the strength of the gypsum continuous phase and theobvious improvement of the interfacial bonding strength between the particle reinforcement and the gypsum continuous phase.The microscopic images by scanning electron microscope indicated that gypsum crystals in particle-gypsum composites wereslender, when the new preparation process was employed. The gypsum crystals interlaced among them, and the contact area ofthe gypsum crystals was increased greatly with the increase of MUF content. Therefore, the gypsum continuous phase wasstrengthened. The amount of the gypsum on the surface of the wood particles was significantly increased with the increase ofMUF content due to the bonding performance of MUF resin.

       

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