Structural assembly board and method of manufacturing same
A composition for use in making a structural assembly board, a structural assembly made from the composition, and a method of making the structural assembly board is provided. The composition includes magnesium oxide having purity of 94-98 wt %; magnesium chloride; and water. The magnesium oxide has at least two different particles sizes. The composition and method of making the structural assembly board promote formation of 5MgO.MgCl 2 .8H 2 O to improve structural qualities of the structural assembly board.
1. A composition for use in making a structural assembly board, comprising:
Magnesium oxide (MgO) having purity of 94-98 wt %;
Magnesium chloride (MgCl 2 ); and
Water,
wherein the MgO has at least two different particles sizes,
wherein the molar ratio of MgO:MgCl 2 :H 2 O is 5-9:1:10-20.
2. The composition of claim 1 , wherein the molar ratio of MgO:MgCl 2 :H 2 O is about 5.5:1:12.5.
3. The composition of claim 1 , wherein the MgO comprises greater than 96.5 wt % MgO.
4. The composition of claim 1 , further comprising fiber.
5. The composition of claim 4 , wherein the fiber is at least one of basalt, polypropylene, hemp, and/or flax.
6. The composition of claim 1 , further comprising Fly ash.
7. The composition of claim 1 , further comprising Perlite.
8. The composition of claim 7 , wherein the Perlite has a particle size of 0.5 mm-2 mm.
9. The composition of claim 1 , further comprising at least one of carboxylic functionalized amphiphilic molecules, phosphonic functionalized amphiphilic molecules, and/or polymers.
10. The composition of claim 1 , further comprising NaH 2 PO 4 , KH 2 PO 4 , H 3 PO 4 or sodium silicate.
11. A structural assembly board made from the composition of claim 1 .
12. A method of manufacturing a structural assembly board, the method comprising:
dissolving magnesium chloride in water to form a brine solution;
dissolving MgO, having a purity of 94-98 wt % MgO, endothermically in the solution to form a cement mixture, the MgO having at least two different particles sizes;
mixing the cement mixture; and
curing the cement mixture in a mould.
13. The method of claim 12 , wherein the molar ratio of MgCl 2 :H 2 O is 1:12-13.
14. The method of claim 12 , further comprising adding aggregate and reinforcing fibers to the solution.
15. The method of claim 12 , further comprising cooling the solution to a temperature less than or equal to 24° C. before dissolving MgO in the solution.
16. The method of claim 12 , wherein the MgO dissolved in the solution has a purity of greater than 96.5%.
17. The method of claim 12 , wherein the MgO comprises MgO particles having at least two different surface areas.
18. The method of claim 12 , wherein the MgO has a first MgO particle having a surface area of 30 m 2 /g and a second MgO particle having a surface area of 70 m 2 /g.
19. The method of claim 12 , wherein the cement mixture is cured with at least one conditions selected from 50-90% humidity, 30-60° C., 20-30° C., and a curing time of at least 24 hours.