Base material of low carbon footprint stone-like coating

Abstract

A primary material for a low-carbon footprint stone-like coating, used to provide a stone-like texture, comprises an inorganic aggregate, which is a silicate obtained by reprocessing silica-containing waste. Therefore, the primary material of this low-carbon footprint stone-like coating possesses characteristics such as greater environmental friendliness, lower carbon footprint, higher hardness, and higher wear resistance.

Description

[Technical Field]

[0001] This work relates to a stone-like coating, and more particularly to the main material of a low-carbon footprint stone-like coating. [Previous Technology]

[0002] As stone is one of the building materials favored by many Chinese people, the waste costs and natural resources caused by its non-renewable nature, as well as the excessive load on building structures due to its weight, have gradually been recognized, and alternative methods are being sought.

[0003] The early "gravel washing" method mainly involved mixing natural gravel with cement, stirring thoroughly, and then having workers apply it evenly to the building's walls or floors with a scraper. After the cement and natural gravel mixture dried slightly and gradually hardened, it was then scrubbed with a sponge or sprayed with pressurized mist water. Because the application process was quite time-consuming and labor-intensive, it increased the construction cost. After the application was completed, it was necessary to scrub or rinse off the excess mud, which greatly increased the procedures and made the process relatively troublesome. Finally, the scrubbing or rinsing process generated a large amount of wastewater, which would pollute the construction site environment and was relatively environmentally unfriendly.

[0004] To solve the aforementioned problems, some manufacturers have developed sprayable stone-like coatings, such as the stone-like coating disclosed in conventional technology No. TW201249671A. Figure 1 shows the formula and flow chart of the conventional stone-like coating. As shown in Figure 1, it is mainly composed of a resin (91), a seaweed (92), a water (93), a stone powder (94), a sand (95), a cement (96), and several multi-colored flakes (97). After spraying, the multi-colored flakes (97) are arranged in a staggered or layered manner to create the texture of natural stone with irregular surface patterns.

[0005] However, although the above-mentioned conventional technology can achieve the appearance effect of imitation stone, the components of the conventional technology are not renewable resources, and there is no waterproof and weather-resistant function. Moreover, the multi-colored film (97) is limited by size, and the resolution of the imitation stone effect is limited, and the realism is relatively low.

[0006] In view of the above and other issues, there is still room for improvement in the prior art. [Summary of the Invention]

[0007] To solve the above and other problems, the main purpose of this invention is to provide a low-carbon footprint stone-like coating material to improve upon previous technologies.

[0008] One purpose of this invention is to provide a low-carbon footprint stone-like coating material whose inorganic aggregate is obtained from silicon-containing waste through recycling, making it more environmentally friendly and with a low carbon footprint.

[0009] Another objective of this invention is to provide a main material for a low-carbon footprint stone-like coating that has higher hardness and higher wear resistance.

[0010] Another objective of this invention is to provide a low-carbon footprint stone-like coating with an adhesive resin as the primer, which can be applied evenly to building walls or floors without the need for a scraper, thus reducing application costs compared to previous technologies.

[0011] Another objective of this invention is to provide a low-carbon footprint stone-like coating with an acrylic resin intermediate layer that improves durability and toughness compared to previous technologies.

[0012] Another objective of this invention is to provide a low-carbon footprint stone-like coating, with the main material consisting of color paste and inorganic aggregate (white sand) as the main spray coating layer, which can improve the stone-like realism compared to previous technologies.

[0013] Another objective of this invention is to provide a low-carbon footprint stone-like coating that can be adapted to different substrate materials to close the pores of the substrate, reduce dust impact, and reduce capillary effect.

[0014] To achieve the aforementioned and other inventive objectives, this invention provides a low-carbon footprint stone-like coating suitable for a substrate, comprising: a primer layer for adhering to the substrate; a base layer coated on top of the previous layer for providing a stone-like texture; and a topcoat layer coated on the base layer for protecting the base layer, wherein the base layer comprises an inorganic aggregate, which is a silicate or silicon dioxide obtained by reprocessing or recycling silica-containing waste.

[0015] Preferably, the primer layer can be formulated to match the substrate, and can be either transparent or colored.

[0016] In one embodiment, the inorganic aggregate is spherical silica obtained from silica-containing waste through reprocessing or recycling. Preferably, the spherical silica can be obtained directly from the silica-containing waste through a single processing step, without the need for secondary or tertiary processing (which would increase carbon emissions). Preferably, the diameter of the spherical silica obtained after reprocessing is between 3 and 30 μm. Preferably, the reprocessing temperature is between 850 and 1350°C. The reprocessing conditions may affect the whiteness or hardness of the silicate or silica; therefore, appropriate processing conditions need to be selected or adjusted according to the substrate to which the stone-like coating is applied.

[0017] In one embodiment, the particle size of the spherical silicon dioxide is about 10 to 15 μm, and the sphericity of the spherical silicon dioxide is ≥80%.

[0018] In one embodiment, the inorganic aggregate is silicon carbide obtained by reprocessing the silicon-containing waste.

[0019] In one embodiment, the main material layer comprises about 0% to 10% by weight of color paste, about 5% to 65% by weight of inorganic aggregate and about 5% to 35% by weight of resin.

[0020] In one embodiment, the main material layer further contains a sufficient amount of water.

[0021] In one embodiment, the color paste is composed of the color scheme of a stone-like object.

[0022] In one embodiment, the primer layer contains an adhesive resin selected from polyurethane, ethylene vinyl acetate copolymer, polyurethane acrylate, polyacrylate, and epoxy resin.

[0023] In one embodiment, the primer layer has strong alkali resistance properties for adhering to the substrate comprising a new substrate and an old substrate.

[0024] In one embodiment, it further includes an intermediate coating layer applied to the primer layer for the main material layer to be applied to the intermediate coating layer.

[0025] In one embodiment, when the primer layer is transparent, the intermediate coating layer contains the inorganic aggregate.

[0026] In one embodiment, the intermediate coating contains acrylic resin and has high toughness properties to improve the bonding durability of the primer layer and the main material layer.

[0027] In one embodiment, the topcoat layer has waterproof, scratch-resistant, alkali-resistant and UV-resistant properties.

[0028] In one embodiment, the substrate includes glass, cement, metal, steel structure, calcium silicate board, ceramic tile, kiln-fired plate, slate or other imitation stone slab.

[0029] In order to achieve the aforementioned and other inventive objectives, this invention provides a main material for a low-carbon footprint imitation stone coating, which provides an imitation stone texture for the low-carbon footprint imitation stone coating. The main material includes an inorganic aggregate, which is a silicate obtained by reprocessing silica-containing waste.

[0030] In one embodiment, the inorganic aggregate is spherical silicon dioxide obtained by reprocessing the silicon-containing waste, with a diameter between 3 and 30 μm and a reprocessing temperature between 850 and 1350°C.

[0031] In one embodiment, the particle size of the spherical silicon dioxide is about 10~15 μm, and the sphericity of the spherical silicon dioxide is ≥80%.

[0032] In one embodiment, the inorganic aggregate is silicon carbide obtained by reprocessing the silicon-containing waste.

[0033] In one embodiment, the main material comprises about 0% to 10% by weight of color paste, about 5% to 65% by weight of inorganic aggregate and about 5% to 35% by weight of resin.

[0034] In one embodiment, the main material complies with the requirements of the Green Building Materials Label.

[0035] The directions or similar terms used herein, such as front, back, left, right, top, bottom, inside, outside, side, etc., are primarily for reference to the diagrams and are used only to assist in explaining and understanding the various embodiments of this invention, and are not intended to limit this invention. Furthermore, the articles used for elements or components described herein, such as "a" or "the," are for simplification only and should be interpreted in this invention as including one or at least one, and a single concept also includes plural cases, unless otherwise clearly intended to the contrary.

Implementation Method

[0037] To make the above and other objects, features and advantages of this invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Symbols that are indicated by the same symbols in different drawings are considered identical and their descriptions may be omitted.

[0038] Figure 2 is a schematic diagram of the low-carbon footprint stone-like coating of this embodiment. Please refer to Figure 2. The low-carbon footprint stone-like coating of this embodiment is applicable to a substrate (W). The low-carbon footprint stone-like coating of this embodiment includes: a primer layer (11) for adhering to the substrate (W); a main material layer (13) coated on the previous layer to provide a stone-like texture; and a topcoat layer (14) coated on the main material layer (13) to protect the main material layer (13). The main material layer (13) includes an inorganic aggregate (132), which is a silicate or silicon dioxide obtained after recycling silicon-containing waste.

[0039] As a major global semiconductor manufacturing hub, Taiwan has a very high demand for silicon dioxide. Consequently, the amount of silicon-containing waste generated is also considerable. The inorganic aggregate (132) is very helpful for the protection of the Earth's ecology by recycling silicon-containing waste.

[0040] Preferably, the inorganic aggregate (132) is spherical silicon dioxide obtained from silicon-containing waste through recycling, with a diameter between 3 and 30 μm, and the reprocessing temperature is between 850 and 1350°C. In this way, the desired silicon dioxide is refined.

[0041] Among them, the spherical silicon dioxide is a fine nano-scale material with a particle size of about 10~15 μm and a true sphericity of ≥80%. Through actual application, compared with the raw material, its flexural strength has increased from 14.2 MPa to 34.4 MPa, and its refractoriness can reach SK29 (1650˚C) or higher, effectively improving the overall material performance.

[0042] Table 1 below is a comparison of the materials of the embodiments and comparative examples of this invention. As can be seen from Table 1, the conventional comparative example B is too large and the comparative example C is too small.

[0043] Table 1 characteristic Material A - Example Material B - Comparative Example Material C - Comparative Example Appearance powder powder powder Crystallinity description amorphous amorphous amorphous Average particle size μm 25.30 37.89 1.36 D10 μm 2.39 21.45 0.58 D50 μm 19.92 34.72 1.24 D90 μm 57.62 58.06 2.29 shape spherical spherical spherical color White White White Specific surface area m 2 / g <5 <5 <5 Heat loss rate % <0.3 <0.3 <0.3

[0044] Another embodiment of this invention is A1, as shown in Table 2 below.

[0045] Table 2 A1 Material - Examples Feature Items unit Features / Specifications Detection methods Appearance Powder Crystal structure Amorphous shape Spherical color White Average particle size μm 30 Particle size D10 μm >7 Laser scattering Laser scattering Particle size D50 μm <50 Laser scattering Laser scattering Particle size D90 μm <80 Laser scattering Laser scattering Specific surface area (SSA) (BET) m 2 / g 0.7~1.3 Loss on ignition (Lol) % <1 Moisture content % <0.5 Hygrometer Moisture meters pH value 7~9 pH meter pH meter electrical conductivity us / cm <10 conductivity meter Conductivity meter Silicon dioxide purity % >98.5 Energy dispersive X-ray fluorescence EDXRF

[0046] Another embodiment of this invention uses A2 material, as shown in Table 3 below.

[0047] Table 3 A2 Material - Examples Feature Items unit Features / Specifications Detection methods Appearance Powder Crystal structure Amorphous shape Spherical color White Particle size D50 μm <30 Laser scattering Laser scattering Specific surface area (SSA) (BET) m 2 / g 0.8~1.3 Loss on ignition (Lol) % <1 Moisture content % <0.5 Hygrometer Moisture meters pH value 7~9 pH meter pH meter electrical conductivity μs / cm <40 conductivity meter Conductivity meter Silicon dioxide purity % >98.5 Energy dispersive X-ray fluorescence EDXRF

[0048] Specific Surface Area (SSA) refers to the total surface area of ​​a solid per unit mass. The specific surface area of ​​a material is measured using a BET (Brunauer Emmett Teller) instrument and gas adsorption technology. A high specific surface area helps to improve the structural strength of the material because more surface area can provide more binding points or reaction sites, making the material structure more compact. As shown in Tables 1 to 3, material A2 has a better specific surface area of ​​0.8 to 1.3 m2 / g.

[0049] The silicon dioxide purity of A2 material is >98.5%. High-purity silicon dioxide means that there are almost no other impurities in the material, which helps to improve the structural strength and stability of the material. High-purity silicon dioxide can provide better mechanical strength and chemical resistance.

[0050] Therefore, compared with other materials, the inorganic aggregate (132) using A2 material has a better structure due to its high specific surface area and high purity silicon dioxide.

[0051] Furthermore, since the inorganic aggregate (132) is obtained from silicon-containing waste through recycling, the inorganic aggregate (132) undergoes at least two processing steps, including: firstly producing a silicon-containing product, and then reprocessing it through recycling. The inorganic aggregate (132) after the two processing steps has better hardness, which is similar to that of silicon carbide. Silicon carbide (SiC) has a Mohs hardness of about 9, second only to diamond and boron carbide, and has high hardness and high wear resistance. Silicon carbide materials are chemically and mechanically stable, and their low energy consumption, high power, high temperature resistance, corrosion resistance and wear resistance make them one of the popular third-generation semiconductor materials.

[0052] Preferably, the main material layer (13) comprises approximately 0% to 10% by weight of color paste (131), approximately 5% to 65% by weight of inorganic aggregate (132), and approximately 5% to 35% by weight of resin (133). In this way, it can imitate stone while also possessing other properties such as high hardness, high temperature resistance, and wear resistance.

[0053] More preferably, the main material layer (13) also contains sufficient water to ensure that the main material layer (13) has a certain degree of fluidity so that it can be sprayed by a spray gun.

[0054] More preferably, the color paste (131) is composed of the color matching of a stone imitation object. The computer first analyzes the color matching ratio of the stone imitation object, and then uses the color paste (131) to imitate the color and texture of the stone imitation object.

[0055] Preferably, the primer layer (11) contains an adhesive resin selected from polyurethane, ethylene vinyl acetate copolymer, polyurethane acrylate, polyacrylate, and epoxy resin. This allows for diverse physical properties suitable for different environments, and excellent adhesion properties ensure good adhesion between the primer layer (11) and subsequent coatings or the substrate (W), enhancing overall durability and performance.

[0056] More preferably, the primer layer (11) has strong alkali resistance properties for adhesion to the substrate (W) including both new and old substrates. Since the main component of cement and concrete is calcium oxide, which is a highly alkaline substance with a pH value usually higher than 12, in humid or water-contact environments, cement will release calcium hydroxide during the reaction with water, forming a highly alkaline environment on the wall surface. Without strong alkali resistance properties, the protective performance will be reduced and structural problems will occur due to reduced adhesion, incomplete hardening, and chemical degradation caused by alkalinity.

[0057] Preferably, it further includes an intermediate coating (12) applied to the primer layer (11) so that the main material layer (13) can be applied to the intermediate coating (12). This provides a base color and improves durability and toughness.

[0058] More preferably, when the primer layer (11) is transparent, the intermediate layer (12) includes the inorganic aggregate (132). This ensures that the background color of the imitation stone on the substrate (W) is not obscured by the color of the main material layer (13), preventing the original color of the substrate (W) from being unable to be covered by the background color of the imitation stone.

[0059] More preferably, the intermediate coating (12) contains acrylic resin and has high toughness properties to improve the bonding durability between the primer layer (11) and the main material layer (13). This reduces coating cracks caused by expansion or contraction.

[0060] Preferably, the topcoat layer (14) has waterproof, scratch-resistant, alkali-resistant and UV-resistant properties. In this way, it can prevent adverse effects caused by harsh environments such as storms, sandstorms, extreme cold and heat and scorching sun.

[0061] Preferably, the substrate (W) includes glass, cement, metal, steel structure, calcium silicate board, ceramic tile, kiln-fired slab, slate, or other imitation stone. This covers most common building surface materials.

[0062] Preferably, the main material of the low-carbon footprint stone-like coating is used to provide a stone-like texture for the low-carbon footprint stone-like coating. The main material includes an inorganic aggregate, which is a silicate obtained by reprocessing silica-containing waste. In this way, the environmental protection purpose of resource reuse is achieved.

[0063] More preferably, the inorganic aggregate is spherical silicon dioxide obtained by reprocessing the silicon-containing waste, with a diameter between 3 and 30 μm, and the reprocessing temperature between 850 and 1350°C. This allows for the refining of the desired silicon dioxide.

[0064] More preferably, the particle size of the spherical silicon dioxide is about 10 to 15 μm, and the sphericity of the spherical silicon dioxide is ≥80%. This improves flowability and uniformity, enhances material properties, and strengthens durability.

[0065] More preferably, the inorganic aggregate is silicon carbide obtained by reprocessing the silicon-containing waste. This gives the inorganic aggregate high hardness, high temperature resistance, corrosion resistance and wear resistance.

[0066] More preferably, the main material comprises approximately 0% to 10% by weight of color paste, approximately 5% to 65% by weight of inorganic aggregate, and approximately 5% to 35% by weight of resin. This allows it to imitate stone while also possessing other properties such as high hardness, high temperature resistance, and wear resistance.

[0067] More preferably, the main material complies with the requirements of the Green Building Materials Label. This responds to the government's objectives for establishing Green Building Materials, namely: 1. Green building materials are environmentally friendly building materials: ensuring that Green Building Materials Label products have low environmental impact throughout their life cycle; 2. Green building materials are harmless to human health: ensuring that they do not cause harm to human health; and 3. Green building materials should meet relevant specifications and standards: their quality should meet regulatory and general functional requirements.

[0068] Figure 3 is an electron microscope magnification of the silica of this invention embodiment. Please refer to Figure 3. Using a scanning electron microscope (SEM), an electron microscope that generates an image of the sample surface by scanning the sample surface with a focused electron beam, the appearance of the spherical silica of this invention is magnified in detail. The shape with a true sphericity ≥80% is different from that of ordinary silica. Natural quartz silica exists in crystalline form and has a hexagonal prism or hexahedral structure. Common sand is also silica, and its appearance is usually irregular in shape and has rough edges. The spherical silica of this invention is close to a true sphere and is fine, with a high specific surface area. More surface area can provide more bonding points or reaction sites, making the structure of the material more compact.

[0069] Figure 4 is a schematic diagram of the construction process of the low-carbon footprint stone-like coating of this invention embodiment. Please refer to Figure 4. The low-carbon footprint stone-like coating of this invention embodiment is suitable for substrates (W), such as building walls or floors. The construction method includes: (S21) applying a primer layer (11) to the substrate (W) using a brush, roller or spray gun; (S22) applying a mid-coat layer (12) to the primer layer (11) using a spray gun; (S23) applying a main material layer (13) to the mid-coat layer (12) using a spray gun; (S24) applying a topcoat layer (14) to the main material layer (13) using a brush, roller or spray gun.

[0070] Although the present invention has been disclosed using the above preferred embodiments, it is not intended to limit the present invention. Any modifications and alterations made by those skilled in the art to the above embodiments without departing from the spirit and scope of the present invention shall still fall within the scope of the technology protected by the present invention. Therefore, the scope of protection of the present invention shall include all changes within the meaning and equivalent scope of the appended claims. When the above embodiments can be combined, the present invention includes any combination of implementation states. [Simplified Explanation of the Diagram]

[0036] The embodiments of this invention will be described with the following simple explanations and accompanying drawings: Figure 1 is a formula and flow chart of conventional stone-like coatings. Figure 2 is a schematic diagram of the low-carbon footprint stone-like coating of this invention. Figure 3 is an electron microscope magnified image of silicon dioxide of this invention. Figure 4 is a schematic diagram of the construction process of the low-carbon footprint stone-like coating of this invention.

Claims

1. A main material for a low-carbon footprint stone-like coating, directly or indirectly attached to a substrate (W) to provide a stone-like texture for the coating, the main material comprising an inorganic aggregate, which is a silicate obtained by reprocessing silica-containing waste; wherein, The silicate is spherical silica with a particle size in the micrometer range and a particle size D50 of less than 30 μm, a true sphericity of greater than or equal to 80%, and a specific surface area between 0.8 and 1.3 m2 / g.

2. The main material of the low-carbon footprint stone-like coating as described in claim 1, wherein, The diameter of the spherical silicon dioxide is between 3 and 30 μm, and the reprocessing temperature of the silicon-containing waste during the reprocessing process is between 850 and 1350°C.

3. The main material of the low-carbon footprint stone-like coating as described in claim 2, wherein, The particle size of the spherical silicon dioxide is between 10 and 15 μm.

4. The main material of the low-carbon footprint stone-like coating as described in claim 2, wherein, The main material has a bending strength of 34.4 MPa and a fire resistance of over 1650˚C.

5. The main material of the low-carbon footprint stone-like coating as described in any one of claims 1 to 4, wherein, The inorganic aggregate is silicon carbide obtained by reprocessing the silicon-containing waste.

6. The main material of the low-carbon footprint stone-like coating as described in any one of claims 1 to 4, wherein, The main material comprises approximately 0% to 10% by weight of color paste, approximately 5% to 65% by weight of inorganic aggregate, and approximately 5% to 35% by weight of resin.

7. The main material of the low-carbon footprint stone-like coating as described in any one of claims 1 to 4, wherein, The main material is directly or indirectly attached to a primer layer (11), which contains an adhesive resin and has strong alkali resistance properties. The primer layer (11) is used to attach to the substrate (W).

8. The main material of the low-carbon footprint stone-like coating as described in claim 7, wherein, An intermediate coating (12) is attached to the primer layer (11) so that the main material can be indirectly attached to the primer layer (11). The intermediate coating (12) contains acrylic resin and has high toughness characteristics to improve the bonding durability between the primer layer (11) and the main material.

9. The main material of the low-carbon footprint stone-like coating as described in claim 8, wherein, When the primer layer (11) is transparent, the intermediate layer (12) contains the inorganic aggregate of the main material.

10. The main material of the low-carbon footprint stone-like coating as described in any one of claims 1 to 4, wherein, A topcoat layer (14) is attached to the main material to protect it. The topcoat layer (14) has waterproof, scratch-resistant, alkali-resistant and UV-resistant properties.

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