Flexible sheet composition for interior and exterior wall decoration, flexible sheet and preparation method and application thereof

Abstract

The invention relates to the technical field of building materials, and discloses a flexible sheet composition for interior and exterior wall decoration, a flexible sheet as well as a preparation method and application of the flexible sheet. The composition comprises a component A and a component B, the component A is prepared from the following components in percentage by mass: 4 to 12 percent of water-based polymer emulsion, 10 to 30 percent of geopolymer, 1 to 3 percent of silane coupling agent, 2.6 to 9.6 percent of auxiliary agent, 50 to 70 percent of aggregate and 8 to 17 percent of water; and the component B is an alkali activator. According to the flexible sheet for interior and exterior wall decoration, the geopolymer and the water-based polymer emulsion are adopted as raw materials, the advantages of the geopolymer and the water-based polymer emulsion are integrated into a flexible sheet product, and the purposes of reducing the water absorption rate, improving the water resistance and having flexibility are achieved.

Description

Technical Field

[0001] The invention relates to the technical field of building materials, and in particular to a flexible sheet material composition for interior and exterior wall decoration, a flexible sheet material and a preparation method and application thereof. Background Art

[0002] After nearly 30 years of development, it is increasingly difficult for domestic architectural coatings to achieve breakthroughs in decorative effects. The emerging flexible architectural sheets not only have the rich textures of natural building materials (wood, stone), but also have a certain degree of flexibility to adapt to the decorative protection of special-shaped parts of buildings. Commercially available flexible sheets are basically produced by adding a small amount of emulsion to inert fillers, grouting into the mold, and reinforced with mesh cloth, non-woven fabrics, etc., and then dried at high temperature.

[0003] The performance requirements of flexible sheets usually adopt two standards: JC / T 2219-2014 Modified Inorganic Powder Composite Building Facing Sheet and JG / T 540-2017 Flexible Imitation Stone Facing Material for Buildings. The water absorption rate of the former is not higher than 15%, and the water absorption rate of the latter is not higher than 8%. In fact, many flexible sheet products on the market basically use JC / T 2219-2014 standard as the product quality control standard. A few products use the method of adding inert organic silicone water repellent to temporarily reduce the water absorption rate to less than 8%. This solution mainly uses the inert organic silicone water repellent to migrate on the surface of the product, creating the illusion of low water absorption of the product. Its main disadvantages are two aspects: first, the inert water repellent has poor durability, and the water repellent function will gradually disappear with the extension of use time; second, the inert water repellent migrates on the surface of the flexible sheet, causing the safety hazard of the flexible sheet not being firmly bonded. Flexible sheets produced by this formula and process generally have the disadvantages of low water resistance and high water absorption. In practical applications, especially in rainy weather conditions in the south or in building structures prone to water accumulation, they are prone to bulging and falling off, posing a great safety hazard.

[0004] Therefore, there is an urgent need to develop a flexible sheet material for interior and exterior wall decoration with low water absorption and high water resistance. Summary of the invention

[0005] The purpose of the present invention is to overcome the problems existing in the prior art and to provide a flexible sheet material composition for interior and exterior wall decoration, a flexible sheet material and a preparation method and application thereof.

[0006] The invention adopts geopolymer and high molecular polymer through interpenetrating cross-linking reaction to prepare a sheet material with high water resistance, low water absorption and certain flexibility.

[0007] In order to achieve the above-mentioned object, the first aspect of the present invention provides a flexible sheet material composition for interior and exterior wall decoration, wherein the composition comprises component A and component B;

[0008] The component A comprises the following components by mass percentage: 4-12% aqueous polymer emulsion, 10-30% geopolymer, 1-3% silane coupling agent, 2.6-9.6% additive, 50-70% aggregate and 8-17% water;

[0009] The B component is a base activator.

[0010] The second aspect of the present invention provides a flexible sheet for interior and exterior wall decoration made from the composition according to the first aspect.

[0011] The third aspect of the present invention provides a method for preparing a flexible sheet for interior and exterior wall decoration according to the second aspect, wherein the method comprises: mixing the components of component A and the components of component B respectively to obtain slurry A and slurry B, mixing slurry A and slurry B according to a mass ratio, spraying, scraping or rolling them on a mold or a carrier surface, and drying and curing them at 80-120°C to obtain the flexible sheet for interior and exterior wall decoration.

[0012] The fourth aspect of the present invention provides the use of the flexible sheet material according to the second aspect or the flexible sheet material prepared according to the preparation method according to the third aspect in interior and exterior wall decoration.

[0013] Through the above technical solution, the beneficial technical effects achieved by the present invention are as follows:

[0014] (1) The flexible sheet material for interior and exterior wall decoration provided by the present invention uses geopolymer and water-based polymer emulsion as raw materials, and integrates the advantages of the two into a flexible sheet material product, thereby achieving the purpose of reducing water absorption, improving water resistance and having flexibility.

[0015] (2) While improving product performance, the present invention increases production capacity by at least 30%, effectively reducing the amount of cement and high molecular polymers used, thereby achieving the goal of carbon reduction, which is in line with the direction of future global economic development. DETAILED DESCRIPTION

[0016] The endpoints and any values ​​of the ranges disclosed in this article are not limited to the precise ranges or values, and these ranges or values ​​should be understood to include values ​​close to these ranges or values. For numerical ranges, the endpoint values ​​of each range, the endpoint values ​​of each range and the individual point values, and the individual point values ​​can be combined with each other to obtain one or more new numerical ranges, which should be considered as specifically disclosed in this article.

[0017] The first aspect of the present invention provides a flexible sheet material composition for interior and exterior wall decoration, wherein the composition comprises component A and component B;

[0018] The component A comprises the following components by mass percentage: 4-12% aqueous polymer emulsion, 10-30% geopolymer, 1-3% silane coupling agent, 2.6-9.6% additive, 50-70% aggregate and 8-17% water;

[0019] The B component is a base activator.

[0020] The concept of geopolymer was proposed by the Frenchman Davidovits as early as the 1970s. It is an inorganic polymer with a three-dimensional network structure composed of AlO4 and SiO4 tetrahedral structural units. Its chemical formula is Mn{-(SiO2)zAlO2} n ·wH2O, amorphous to semi-crystalline, belongs to non-metallic materials. High molecular polymers are also widely used in the field of construction, with molecular weights as high as hundreds of thousands. They have strong sealing and water isolation functions and are very decorative, but they have defects in durability and water resistance.

[0021] The invention uses geopolymer (which can give flexible sheets excellent mechanical properties and resistance (weather resistance, acid and alkali resistance, water resistance)) and aqueous polymer emulsion (which can give flexible sheets excellent bending properties and sealing and water-proof properties) as raw materials, utilizes common homologous active groups in the two to react (under specific process conditions (temperature, humidity, reaction time, etc.)) to form a cross-linked interpenetrating network structure, and obtains a highly water-resistant, low water-absorbent and flexible sheet, which can completely overcome the shortcomings of low water resistance and high water absorption of existing flexible sheets and solve the problem of potential safety hazards in practical applications.

[0022] The component A of the present invention does not react before being mixed with the component B at room temperature, can be toned and stored for a long time, and the component B does not react at room temperature and can be stored for a long time, but needs to be isolated from air and other acidic substances.

[0023] In some embodiments of the present invention, the mass ratio of component A to component B is 1000:50-200, preferably 1000:80-100. In the present invention, the mass ratio can control the viscosity to achieve good workability and control the reaction activity to achieve a suitable operation time.

[0024] In some embodiments of the present invention, the component A comprises the following components by mass percentage: 6-12% aqueous polymer emulsion, 25% geopolymer, 1% silane coupling agent, 6% additive, 45% aggregate and 11-17% water.

[0025] In some embodiments of the present invention, the aqueous polymer emulsion is an emulsion having calcium ion stability, preferably at least one of a styrene-acrylic emulsion, a pure acrylic emulsion and a silicone-acrylic emulsion.

[0026] In some embodiments of the present invention, the aqueous polymer emulsion has a solid content of 40-60% and a glass transition temperature of -20°C to 10°C.

[0027] In some embodiments of the present invention, the geopolymer is selected from at least one of blast furnace slag powder, fly ash and metakaolin, preferably blast furnace slag powder.

[0028] In some embodiments of the present invention, the average particle size of the geopolymer is 325-1250 mesh.

[0029] In some embodiments of the present invention, the silane coupling agent is selected from at least one of γ-aminopropyltriethoxysilane (KH550), γ-glycidoxypropyltrimethoxysilane (KH560) and γ-methacryloxypropyltrimethoxysilane (KH570).

[0030] In some embodiments of the present invention, the aggregate is graded sand.

[0031] In some embodiments of the present invention, the auxiliary agent is selected from at least one of a dispersant, an anti-settling agent, a leveling agent, a defoamer, a thickener, a toner and a water reducing agent.

[0032] In some embodiments of the present invention, the dispersant is selected from non-ionic dispersants.

[0033] In some embodiments of the present invention, the anti-settling agent is selected from bentonite anti-settling agents.

[0034] In some embodiments of the present invention, the leveling agent is selected from acrylic leveling agents.

[0035] In some embodiments of the present invention, the defoaming agent is selected from mineral oil defoaming agents.

[0036] In some embodiments of the present invention, the thickener is selected from alkali swelling thickeners.

[0037] In some embodiments of the present invention, the toner is selected from at least one of titanium dioxide and color paste.

[0038] In some embodiments of the present invention, the water reducer is selected from at least one of a naphthalene-based water reducer, a sulfonate-based water reducer and a melamine-based water reducer.

[0039] In some embodiments of the present invention, the additives include the following components by mass percentage: 0.3% dispersant, 0.3% anti-settling agent, 0.3% leveling agent, 0.3% defoaming agent, 0.2-0.4% thickener, 0-5% titanium dioxide, 0.2-1% color paste and 1-2% water reducer.

[0040] In some embodiments of the present invention, the additives include the following components by mass percentage: 0.3% dispersant, 0.3% anti-settling agent, 0.3% leveling agent, 0.3% defoaming agent, 0.4% thickener, 3.4% titanium dioxide and 1% water reducer.

[0041] In some embodiments of the present invention, the alkali activator comprises the following components by mass percentage: 4-20% alkali metal hydroxide, 20-60% alkali metal silicate solution with a mass concentration of 30-40%, and 30-70% water.

[0042] In some embodiments of the present invention, the alkali metal hydroxide is selected from at least one of lithium hydroxide, sodium hydroxide and potassium hydroxide.

[0043] In some embodiments of the present invention, the alkali metal silicate solution is selected from at least one of a sodium silicate solution, a potassium silicate solution and a lithium silicate solution, and the modulus is preferably 1.5-3.0.

[0044] In some embodiments of the present invention, the alkali activator comprises the following components by mass percentage: 4-10% alkali metal hydroxide, 30-36% alkali metal silicate solution with a mass concentration of 30%, and 60% water.

[0045] In some embodiments of the present invention, the alkaline activator comprises the following components by mass percentage: 6% lithium hydroxide, 34% lithium silicate solution with a mass concentration of 30%, and 60% water.

[0046] The second aspect of the present invention provides a flexible sheet material for interior and exterior wall decoration made from the composition according to the first aspect. The flexible sheet material provided by the present invention has flexibility, low water absorption and high cohesive strength, and can also replace the use of cement materials and reduce the amount of high molecular polymers, thereby achieving the purpose of carbon reduction.

[0047] The third aspect of the present invention provides a method for preparing a flexible sheet for interior and exterior wall decoration according to the second aspect, wherein the method comprises: mixing the components of component A and the components of component B respectively to obtain slurry A and slurry B, mixing slurry A and slurry B according to a mass ratio, spraying, scraping or rolling them on a mold or a carrier surface, and drying and curing them at 80-120°C to obtain the flexible sheet for interior and exterior wall decoration.

[0048] The method of the present invention needs to set the upper temperature limit between different areas, control the drying conditions, and obtain qualified products. The drying procedure includes: baking at 80-90°C for 30-45 minutes, baking at 90-100°C for 30-45 minutes, and baking at 100-120°C for 20-30 minutes; preferably, the humidity is 10-25%.

[0049] The mixing method of slurry A and slurry B described in the present invention is to slowly add slurry B into slurry A under stirring. The mold can be made of silicone rubber, thermoplastic elastomer, PVC, PET, etc., and the carrier can be made of ductile coated felt, non-woven fabric, glass fiber mesh, PET film, etc.

[0050] The fourth aspect of the present invention provides the use of the flexible sheet material according to the second aspect or the flexible sheet material prepared according to the preparation method according to the third aspect in interior and exterior wall decoration.

[0051] According to a particularly preferred embodiment of the present invention, a method for preparing a flexible sheet for interior and exterior wall decoration comprises the following steps:

[0052] (1) Prepare slurry A from the components of component A:

[0053] First, add water to the dispersion tank, add the silane coupling agent at a stirring speed of 300-500rpm, and after dispersion and mixing, add the thickener, dispersant, anti-settling agent, leveling agent, and defoamer to the dispersion tank in turn and stir for 10 minutes. Disperse titanium dioxide and aggregate at a stirring speed of 500-1000rpm, add geopolymer and disperse for 10-20 minutes, then add water reducer and water-based polymer emulsion, and then add appropriate amount of color paste for color adjustment and standby;

[0054] (2) Prepare slurry B from the components of component B:

[0055] First, add water into the dispersion tank, add sodium hydroxide powder under stirring and disperse until it is completely dissolved; add alkali metal silicate solution under slow stirring at 200-500rpm, stir until it is uniform and transparent, and set aside;

[0056] (3) According to the requirements of product flexibility and water absorption, a certain proportion of slurry A and slurry B are selected and weighed, mixed, sprayed, scraped, or rolled on the mold or carrier, and transferred to a drying kiln for drying and curing at 80-120°C, cutting, and packaging.

[0057] The present invention will be described in detail below through examples.

[0058] In the following examples and comparative examples, if no specific conditions are specified, the experiments were carried out under conventional conditions or conditions recommended by the manufacturer. The reagents or instruments used, if no manufacturer is specified, are all conventional products that can be obtained through commercial channels.

[0059] In the following examples, the preparation method of slurry A is:

[0060] First add water into the dispersion tank, add the silane coupling agent at a stirring speed of 300 rpm, and after dispersion and mixing, add the thickener, dispersant, anti-settling agent, leveling agent, and defoaming agent into the dispersion tank in turn and stir for 10 minutes in a dispersed state, disperse titanium dioxide and aggregate at a stirring speed of 1000 rpm, add geopolymer and disperse for 20 minutes, and then add water reducer and emulsion.

[0061] The preparation method of slurry B is:

[0062] First, add water to the dispersion tank, add alkali metal hydroxide powder under stirring until it is completely dissolved; add alkali metal silicate solution under slow stirring at 300rpm, stir until it is uniform and transparent, and set aside. The mass concentration of alkali metal silicate solution is 30%.

[0063] The preparation process of flexible sheets for interior and exterior wall decoration is as follows:

[0064] The prepared slurry A and slurry B were mixed in a mass ratio of 1000:50, sprayed into the mold, and dried and solidified in an oven. The drying procedure included: baking at 90°C for 30 minutes, baking at 100°C for 30 minutes, baking at 120°C for 20 minutes, and the humidity was 10%. Finally, the slurry was cut and packaged.

[0065] Examples 1-8 and Comparative Examples 1-3 respectively prepared flexible sheets for interior and exterior wall decoration using the formulations shown in Table 1 and Table 2.

[0066] Table 1

[0067]

[0068]

[0069] Table 2

[0070]

[0071] Test Case

[0072] In the tests of various flexible sheet materials on the market, we found that the strength of flexible sheets decreased significantly after being soaked in water, and some even became powdery and sticky after being soaked in water for 24 hours. However, in the above two flexible sheet standards (JC / T 2219-2014 and JG / T 540-2017), there are no water resistance test methods and evaluation standards.

[0073] In order to characterize the water resistance, the present invention refers to the flexural strength test method in GB / T 17671-2021 cement mortar strength test method, and adjusts the cross-sectional size of the specimen from 40mm*40mm in the standard to 10mm*10mm, which is closer to the actual size of the flexible sheet.

[0074] Water absorption test: Test in accordance with GB / T9966.3-2020.

[0075] Flexibility test: Test according to GB-T 1748-1979 putty film flexibility test method.

[0076] The results are shown in Table 3.

[0077] Table 3

[0078]

[0079]

[0080] It can be seen from the results in Table 3 that the comparison of Examples 1-3 illustrates the optimal choice of the combination of emulsion and alkali metal, Example 4 illustrates that the effect of styrene + sodium is reduced, Example 5 illustrates that the effect of styrene + potassium is poor (emulsification), Examples 6, 7, and 8 illustrate the effect of increasing the amount of emulsion, and Comparative Examples 1, 2, and 3 illustrate the effect of adjusting the ratio of lithium hydroxide + lithium silicate.

[0081] The preferred embodiments of the present invention are described in detail above, but the present invention is not limited thereto. Within the technical concept of the present invention, the technical solution of the present invention can be subjected to a variety of simple modifications, including the combination of various technical features in any other suitable manner, and these simple modifications and combinations should also be regarded as the contents disclosed by the present invention and belong to the protection scope of the present invention.

Claims

1. A flexible sheet material composition for interior and exterior wall decoration, characterized in that: The composition comprises component A and component B; The component A comprises the following components by mass percentage: 4-12% aqueous polymer emulsion, 10-30% geopolymer, 1-3% silane coupling agent, 2.6-9.6% additive, 50-70% aggregate and 8-17% water; The B component is a base activator.

2. The composition according to claim 1, wherein The mass ratio of component A to component B is 1000:50-200, preferably 1000:80-100; Preferably, the component A comprises the following components by mass percentage: 6-12% aqueous polymer emulsion, 25% geopolymer, 1% silane coupling agent, 6% additive, 45% aggregate and 11-17% water.

3. The composition according to claim 1 or 2, wherein The aqueous polymer emulsion is an emulsion with calcium ion stability, preferably at least one of styrene-acrylic emulsion, pure acrylic emulsion and silicone-acrylic emulsion; Preferably, the aqueous polymer emulsion has a solid content of 40-60% and a glass transition temperature of -20°C to 10°C; Preferably, the geopolymer is selected from at least one of blast furnace slag powder, fly ash and metakaolin, preferably blast furnace slag powder; Preferably, the average particle size of the geopolymer is 325-1250 mesh; Preferably, the silane coupling agent is selected from at least one of γ-aminopropyltriethoxysilane, γ-glycidyloxypropyltrimethoxysilane and γ-methacryloxypropyltrimethoxysilane; Preferably, the aggregate is graded sand.

4. The composition according to any one of claims 1 to 3, wherein The auxiliary agent is selected from at least one of a dispersant, an anti-settling agent, a leveling agent, a defoamer, a thickener, a toner and a water reducing agent; Preferably, the dispersant is selected from nonionic dispersants; Preferably, the anti-settling agent is selected from bentonite anti-settling agents; Preferably, the leveling agent is selected from acrylic leveling agents; Preferably, the defoamer is selected from mineral oil defoamers; Preferably, the thickener is selected from alkali swelling thickeners; Preferably, the toner is selected from at least one of titanium dioxide and color paste; Preferably, the water reducer is selected from at least one of a naphthalene-based water reducer, a sulfonate-based water reducer and a melamine-based water reducer.

5. The composition according to any one of claims 1 to 4, wherein The additives include the following components by mass percentage: 0.3% dispersant, 0.3% anti-settling agent, 0.3% leveling agent, 0.3% defoamer, 0.2-0.4% thickener, 0-5% titanium dioxide, 0.2-1% color paste and 1-2% water reducing agent; Preferably, the additives include the following components by mass percentage: 0.3% dispersant, 0.3% anti-settling agent, 0.3% leveling agent, 0.3% defoaming agent, 0.4% thickener, 3.4% titanium dioxide and 1% water reducing agent.

6. The composition according to any one of claims 1 to 5, wherein The alkali activator comprises the following components by mass percentage: 4-20% alkali metal hydroxide, 20-60% alkali metal silicate solution with a mass concentration of 30-40% and 30-70% water; Preferably, the alkali metal hydroxide is selected from at least one of lithium hydroxide, sodium hydroxide and potassium hydroxide; Preferably, the alkali metal silicate solution is selected from at least one of a sodium silicate solution, a potassium silicate solution and a lithium silicate solution, and the modulus is preferably 1.5-3.0; Preferably, the alkali activator comprises the following components by mass percentage: 4-10% alkali metal hydroxide, 30-36% alkali metal silicate solution with a mass concentration of 30% and 60% water; Preferably, the alkaline activator comprises the following components by mass percentage: 6% lithium hydroxide, 34% lithium silicate solution with a mass concentration of 30%, and 60% water.

7. A flexible sheet for interior and exterior wall decoration made from the composition according to any one of claims 1 to 6.

8. A method for preparing a flexible sheet for interior and exterior wall decoration according to claim 7, characterized in that: The method comprises: mixing the components of component A and the components of component B respectively to obtain slurry A and slurry B, mixing slurry A and slurry B according to a mass ratio, spraying, scraping or rolling slurry on a mold or a carrier surface, drying and curing at 80-120° C. to obtain the flexible sheet for interior and exterior wall decoration.

9. The preparation method according to claim 8, wherein: The drying procedure includes: baking at 80-90°C for 30-45 min, baking at 90-100°C for 30-45 min, and baking at 100-120°C for 20-30 min; Preferably, the humidity is 10-25%.

10. Use of the flexible sheet material according to claim 7 or the flexible sheet material prepared by the preparation method according to claim 8 or 9 in interior and exterior wall decoration.

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