Architectural decorative material and method of making same

Abstract

This invention discloses a building decoration material comprising the following raw materials in parts by weight: 30-50 parts cement; 20-40 parts lightweight sand; 10-20 parts sepiolite fiber; 1-3 parts lubricant; 1-3 parts early-strength agent; 15-25 parts filler; and 30-50 parts water. The sepiolite fiber is loaded with an epoxy resin layer containing hydrophobic particles, wherein the hydrophobic particles are talc powder with epoxy-based silanes grafted onto its surface. This invention, by loading talc-containing epoxy resin onto the surface of sepiolite fiber and combining it with a specific formulation design, yields a building decoration material with excellent bonding strength and durability, which is lightweight, low-carbon, and has broad application prospects.

Description

Technical Field

[0001] This invention belongs to the field of building materials technology, specifically relating to a building decoration material and its preparation method. Background Technology

[0002] Building decoration materials are mainly used to decorate the interior and exterior walls of buildings, construct interior walls, and, in addition to their decorative function, also fulfill some functional requirements. With the increasing demand for environmental protection and sustainable development, lightweight, low-carbon, and environmentally friendly building decoration materials are receiving more and more attention. To reduce the weight of building decoration materials, a common practice is to add low-weight fillers, which not only achieves lightweighting but also provides sound insulation and noise reduction. However, the addition of lightweight materials leads to a decrease in the durability of the building decoration materials, making them prone to detachment and reduced bonding strength.

[0003] Therefore, in response to the aforementioned technical problems, it is necessary to provide further improvements to building decoration materials. Summary of the Invention

[0004] The purpose of this invention is to provide a building decoration material and its preparation method, which has excellent bonding strength and durability.

[0005] To achieve the above objectives, a specific embodiment of the present invention provides the following technical solution:

[0006] A building decoration material comprises the following raw materials in parts by weight: 30-50 parts cement; 20-40 parts lightweight sand; 10-20 parts sepiolite fiber; 1-3 parts lubricant; 1-3 parts early-strength agent; 15-25 parts filler; and 30-50 parts water.

[0007] The sepiolite fiber is loaded with an epoxy resin layer containing hydrophobic particles, which are talc powder with epoxy silane grafted onto its surface.

[0008] In one or more embodiments of the present invention, the sepiolite fibers are processed as follows:

[0009] The sepiolite fibers were soaked in an aqueous solution of ethylenediamine with a mass concentration of 8wt%-10wt%, and then removed and dried to obtain pretreated sepiolite fibers.

[0010] An epoxy resin coating containing hydrophobic particles is sprayed onto the surface of pretreated sepiolite fibers and reacted at 60℃-80℃ for 4-5 hours to obtain sepiolite fibers loaded with an epoxy resin layer.

[0011] In one or more embodiments of the present invention, the mass ratio of the sepiolite fiber to the ethylenediamine aqueous solution is 1:(2-3), and the mass ratio of the pretreated sepiolite fiber to the epoxy resin coating is 1:(3-4).

[0012] In one or more embodiments of the present invention, the epoxy resin coating comprises the following raw materials in parts by weight: 100 parts of bisphenol A type epoxy resin, 15-20 parts of talc powder, 18-25 parts of diluent, and 1-3 parts of defoamer.

[0013] In one or more embodiments of the present invention, the talc powder is processed as follows:

[0014] Talc powder and an ethanol-water solution of epoxysilane with a mass concentration of 3wt%-5wt% were mixed and treated at 70℃-80℃ for 2h-3h, and then dried.

[0015] In one or more embodiments of the present invention, the epoxy silane is at least one of KH-550, KH-560, and KH-570.

[0016] In one or more embodiments of the present invention, the lightweight sand is pretreated:

[0017] Light sand is mixed with a weakly alkaline dopamine solution and reacted for 25-30 hours. The light sand is then removed, washed, and dried to obtain polydopamine-coated light sand.

[0018] A mixture of polydopamine-coated lightweight sand, phosphate ester compounds, and silane coupling agent in an ethanol-water solution at a mass ratio of 1:(2-3):(4-5) was prepared and treated at 70℃-80℃ for 2-3 hours. The treated lightweight sand was then removed, washed, and dried to obtain the treated lightweight sand.

[0019] In one or more embodiments of the present invention, the phosphate ester compound is at least one of dibutyl phosphate, tributyl phosphate, and monobutyl phosphate.

[0020] In one or more embodiments of the present invention, the silane coupling agent is at least one of vinyltrimethoxysilane and vinyltriethoxysilane.

[0021] Another specific embodiment of the present invention provides the following technical solution:

[0022] A method for preparing a building decoration material involves mixing cement, lightweight sand, sepiolite fiber, lubricant, early strength agent, filler, and water according to a specified ratio to obtain the building decoration material.

[0023] Compared with the prior art, the present invention obtains a building decoration material with excellent bonding strength and durability by loading an epoxy resin layer containing talc powder onto the surface of sepiolite fibers and loading phosphate ester compounds onto the surface of lightweight sand. Through the interaction between sepiolite fibers and lightweight sand, and combined with formulation design, it is lightweight, low-carbon, and has broad application prospects. Detailed Implementation

[0024] To enable those skilled in the art to better understand the technical solutions of this invention, the technical solutions in the embodiments of this invention are clearly and completely described below. Obviously, the described embodiments are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this invention.

[0025] A specific embodiment of the present invention provides a building decoration material comprising the following raw materials in parts by weight: 30-50 parts cement; 20-40 parts lightweight sand; 10-20 parts sepiolite fiber; 1-3 parts lubricant; 1-3 parts early strength agent; 15-25 parts filler; and 30-50 parts water; wherein the sepiolite fiber is loaded with an epoxy resin layer containing hydrophobic particles, the hydrophobic particles being talc powder with epoxy silane grafted onto its surface.

[0026] Specifically, cement possesses excellent adhesion and durability, endowing building and decorative materials with bonding strength, compressive strength, wear resistance, and impact resistance. Lightweight sand's lightweight properties reduce the self-weight of building and decorative materials, while also being environmentally friendly and achieving a low-carbon effect. Sepiolite fibers can form a network structure through interweaving in the material system, enhancing the material's bonding strength and reducing the possibility of cracking and detachment. Loading an epoxy resin layer on its surface can, on the one hand, improve the material's bonding strength through the epoxy resin, and on the other hand, reduce the hydrophilicity of the sepiolite fibers, improving their compatibility in the system and enhancing the water resistance of the material after curing. Talc powder has a certain degree of hydrophobicity, which can reduce the hydrophilicity of sepiolite fibers and simultaneously increase the surface roughness of the sepiolite fibers, facilitating the stable loading of the epoxy resin layer onto the sepiolite fiber surface. Furthermore, pre-grafting epoxy silanes onto the talc powder surface can improve the dispersion of talc powder in the epoxy resin layer, allowing it to be uniformly loaded onto the sepiolite surface.

[0027] Further, the talc powder is processed as follows: talc powder is mixed with an ethanol aqueous solution of epoxy silane with a mass concentration of 3wt%-5wt%, and treated at 70℃-80℃ for 2h-3h, then removed and dried.

[0028] Specifically, the epoxy silane is at least one of KH-550, KH-560, and KH-570.

[0029] Further processing of sepiolite fibers is as follows:

[0030] The sepiolite fibers were soaked in an aqueous solution of ethylenediamine with a mass concentration of 8wt%-10wt%, and then removed and dried to obtain pretreated sepiolite fibers.

[0031] An epoxy resin coating containing hydrophobic particles is sprayed onto the surface of pretreated sepiolite fibers and reacted at 60℃-80℃ for 4-5 hours to obtain sepiolite fibers loaded with an epoxy resin layer.

[0032] Specifically, the mass ratio of sepiolite fiber to ethylenediamine aqueous solution is 1:(2-3), and the mass ratio of pretreated sepiolite fiber to epoxy resin coating is 1:(3-4). Through soaking, ethylenediamine can be adsorbed onto the pores and surface of the sepiolite fiber, and then react with the epoxy resin coating to form an epoxy resin layer on the surface of the sepiolite fiber. Furthermore, the epoxy-based silanes loaded on the talc surface, besides improving its compatibility in the system, can further enhance the loading strength of the epoxy resin on the sepiolite fiber surface through reaction with ethylenediamine.

[0033] Furthermore, the talc powder has a mesh size of 1000-1500 mesh, and the sepiolite fiber length is 4-8 mm. By limiting the specifications of both, it helps the talc powder to be effectively loaded onto the surface of the sepiolite fiber.

[0034] Furthermore, the epoxy resin coating comprises the following raw materials in parts by weight: 100 parts of bisphenol A type epoxy resin, 15-20 parts of talc powder, 18-25 parts of diluent, and 1-3 parts of defoamer.

[0035] Specifically, the diluent is selected from acetone, ethylene glycol methyl ether, and propylene glycol methyl ether, and the defoamer is a conventional choice in the field, specifically BYK-A535. Adding diluents and defoamers improves the flowability of the epoxy resin coating, which helps the epoxy resin coating to impregnate the sepiolite fibers.

[0036] Furthermore, the lightweight sand undergoes pretreatment:

[0037] Light sand is mixed with a weakly alkaline dopamine solution and reacted for 25-30 hours. The light sand is then removed, washed, and dried to obtain polydopamine-coated light sand.

[0038] A mixture of polydopamine-coated lightweight sand, phosphate ester compounds, and silane coupling agent in an ethanol-water solution was prepared and treated at 70℃-80℃ for 2-3 hours. After removal, the mixture was washed and dried to obtain the treated lightweight sand.

[0039] Specifically, the phosphate ester compound is at least one of dibutyl phosphate, tributyl phosphate, and monobutyl phosphate, and the silane coupling agent is at least one of vinyltrimethoxysilane and vinyltriethoxysilane. First, active reactive groups are loaded onto the surface of the lightweight sand through polydopamine coating. Then, the phosphate ester compound is loaded onto the surface of the lightweight sand using a silane coupling agent. The phosphate ester groups in the phosphate ester compound interact with the epoxy resin molecular chains, further enhancing intermolecular bonding and improving the adhesive strength of the system.

[0040] Furthermore, the lightweight sand has a particle size of 0.5-1mm. Lightweight sand within this particle size range can effectively fill the network structure constructed by sepiolite fibers. This facilitates the interaction between the phosphate ester compounds on the surface of the lightweight sand and the epoxy resin layer on the surface of the sepiolite fibers, thereby effectively improving the bonding strength of the system.

[0041] Furthermore, the lubricant is at least one of methylcellulose and polyacrylamide; the early strength agent is at least one of calcium formate and calcium chloride; and the filler is at least one of expanded vermiculite and expanded perlite.

[0042] Another specific embodiment of the present invention provides a method for preparing building decoration materials, comprising: mixing cement, lightweight sand, sepiolite fiber, lubricant, early strength agent, filler and water in a certain proportion to obtain building decoration materials.

[0043] The present invention will be further described in detail below with reference to specific embodiments.

[0044] The raw materials used in this invention are: talc powder, 1250 mesh; sepiolite fiber, 4-8 mm; bisphenol A epoxy resin, Jinan Haowen Chemical, model E-128; lightweight sand with a particle size of 0.5-1 mm; and expanded perlite, 800 mesh.

[0045] Preparation Example 1

[0046] Ethanol and water were mixed at a volume ratio of 8:2, and KH-560 was added to prepare a treatment solution with a concentration of 3wt%. Talc powder and the treatment solution were mixed at a mass ratio of 1:3 and treated at 70℃ for 2 hours. After removal, the solution was dried at 50℃ for 30 minutes to obtain pretreated talc powder.

[0047] By weight, 100 parts of bisphenol A type epoxy resin, 15 parts of pretreated talc powder, 18 parts of acetone, and 1 part of defoamer are mixed evenly to obtain a coating.

[0048] Sepiolite fiber and 8wt% ethylenediamine aqueous solution were mixed at a mass ratio of 1:2 and soaked for 1 hour. Then, the sepiolite fiber was removed and air-dried at 30°C for 30 minutes to obtain pretreated sepiolite fiber.

[0049] The coating and pretreated sepiolite fiber were sprayed onto the sepiolite fiber at a mass ratio of 1:3 and reacted at 60°C for 4 hours to obtain sepiolite fiber loaded with an epoxy resin layer.

[0050] Preparation Example 2

[0051] Ethanol and water were mixed at a volume ratio of 8:2, and KH-560 was added to prepare a treatment solution with a concentration of 5wt%. Talc powder and the treatment solution were mixed at a mass ratio of 1:3 and treated at 80℃ for 3 hours. After removal, the solution was dried at 50℃ for 30 minutes to obtain pretreated talc powder.

[0052] By weight, 100 parts of bisphenol A epoxy resin, 20 parts of pretreated talc powder, 25 parts of acetone, and 3 parts of defoamer are mixed evenly to obtain a coating.

[0053] Sepiolite fiber and 10wt% ethylenediamine aqueous solution were mixed at a mass ratio of 1:3 and soaked for 1 hour. Then, the sepiolite fiber was removed and air-dried at 30°C for 30 minutes to obtain pretreated sepiolite fiber.

[0054] The coating and pretreated sepiolite fiber were sprayed onto the sepiolite fiber at a mass ratio of 1:4 and reacted at 80°C for 5 hours to obtain sepiolite fiber loaded with an epoxy resin layer.

[0055] Preparation Example 3

[0056] Tris(hydroxymethyl)aminomethane hydrochloride buffer was prepared and the pH was adjusted to 8.5 with hydrochloric acid. Based on the use of 3g dopamine hydrochloride and 45g light sand per 1L of buffer, dopamine hydrochloride was mixed with the buffer, and then light sand was added. The mixture was reacted for 1 hour and then dried to obtain polydopamine-coated light sand.

[0057] Ethanol and water were mixed at a volume ratio of 8:2, and vinyltrimethoxysilane was added to prepare a 3wt% modified solution. Polydopamine-coated light sand, dibutyl phosphate and the modified solution were mixed at a mass ratio of 1:2:4 and treated at 70°C for 2 hours. After removal, the mixture was washed with water and dried to obtain the treated light sand.

[0058] Preparation Example 4

[0059] Tris(hydroxymethyl)aminomethane hydrochloride buffer was prepared and the pH was adjusted to 8.5 with hydrochloric acid. Based on the use of 3g dopamine hydrochloride and 45g light sand per 1L of buffer, dopamine hydrochloride was mixed with the buffer, and then light sand was added. The mixture was reacted for 1 hour and then dried to obtain polydopamine-coated light sand.

[0060] Ethanol and water were mixed at a volume ratio of 8:2, and vinyltrimethoxysilane was added to prepare a 3wt% modified solution. Polydopamine-coated light sand, tributyl phosphate and the modified solution were mixed at a mass ratio of 1:2.5:5 and treated at 80°C for 2 hours. After removal, the mixture was washed with water and dried to obtain the treated light sand.

[0061] Preparation Example 5

[0062] Tris(hydroxymethyl)aminomethane hydrochloride buffer was prepared and the pH was adjusted to 8.5 with hydrochloric acid. Based on the use of 3g dopamine hydrochloride and 45g light sand per 1L of buffer, dopamine hydrochloride was mixed with the buffer, and then light sand was added. The mixture was reacted for 1 hour and then dried to obtain polydopamine-coated light sand.

[0063] Ethanol and water were mixed at a volume ratio of 8:2, and vinyltrimethoxysilane was added to prepare a 3wt% modified solution. Polydopamine-coated light sand, monobutyl phosphate and the modified solution were mixed at a mass ratio of 1:3:3.5 and treated at 70°C for 3 hours. After removal, the mixture was washed with water and dried to obtain the treated light sand.

[0064] Example 1

[0065] A building decoration material, by weight, comprises 30 parts cement, 36 parts lightweight sand, 10 parts sepiolite fiber (as in Preparation Example 1), 3 parts methylcellulose, 2 parts calcium formate, 15 parts expanded perlite, and 42 parts water. During preparation, the above raw materials are mixed thoroughly to obtain the building decoration material.

[0066] Example 2

[0067] A building decoration material, by weight, comprises 40 parts cement, 40 parts lightweight sand, 16 parts sepiolite fiber (as in Preparation Example 1), 2 parts methylcellulose, 1 part calcium formate, 20 parts expanded perlite, and 30 parts water. During preparation, the above raw materials are mixed thoroughly to obtain the building decoration material.

[0068] Example 3

[0069] A building decoration material, by weight, comprises 50 parts cement, 20 parts lightweight sand, 20 parts sepiolite fiber (as in Preparation Example 1), 1 part methylcellulose, 3 parts calcium formate, 25 parts expanded perlite, and 50 parts water. During preparation, the above raw materials are mixed thoroughly to obtain the building decoration material.

[0070] Example 4

[0071] A building decoration material, by weight, comprises 30 parts cement, 36 parts lightweight sand, 10 parts sepiolite fiber (as in Preparation Example 2), 3 parts methylcellulose, 2 parts calcium formate, 15 parts expanded perlite, and 42 parts water. During preparation, the above raw materials are mixed thoroughly to obtain the building decoration material.

[0072] Example 5

[0073] A building decoration material, by weight, comprises 30 parts cement, 36 parts lightweight sand (as in Preparation Example 3), 10 parts sepiolite fiber (as in Preparation Example 1), 3 parts methylcellulose, 2 parts calcium formate, 15 parts expanded perlite, and 42 parts water. During preparation, the above raw materials are mixed thoroughly to obtain the building decoration material.

[0074] Example 6

[0075] A building decoration material, by weight, comprises 30 parts cement, 36 parts lightweight sand (as in Preparation Example 4), 10 parts sepiolite fiber (as in Preparation Example 2), 3 parts methylcellulose, 2 parts calcium formate, 15 parts expanded perlite, and 42 parts water. During preparation, the above raw materials are mixed thoroughly to obtain the building decoration material.

[0076] Example 7

[0077] A building decoration material, by weight, comprises 30 parts cement, 36 parts lightweight sand (as in Preparation Example 5), 10 parts sepiolite fiber (as in Preparation Example 1), 3 parts methylcellulose, 2 parts calcium formate, 15 parts expanded perlite, and 42 parts water. During preparation, the above raw materials are mixed thoroughly to obtain the building decoration material.

[0078] Comparative Example 1

[0079] A building decoration material, by weight, comprises 30 parts cement, 36 parts lightweight sand, 10 parts sepiolite fiber, 3 parts methylcellulose, 2 parts calcium formate, 15 parts expanded perlite, and 42 parts water. In preparation, the above raw materials are mixed evenly to obtain the building decoration material.

[0080] Comparative Example 2

[0081] By weight, 100 parts of bisphenol A epoxy resin, 18 parts of acetone, and 1 part of defoamer are mixed evenly to obtain a coating.

[0082] Sepiolite fiber and 8wt% ethylenediamine aqueous solution were mixed at a mass ratio of 1:2 and soaked for 1 hour. Then, the sepiolite fiber was removed and air-dried at 30°C for 30 minutes to obtain pretreated sepiolite fiber.

[0083] The coating and pretreated sepiolite fiber were sprayed onto the sepiolite fiber at a mass ratio of 1:3 and reacted at 60°C for 4 hours to obtain sepiolite fiber loaded with an epoxy resin layer.

[0084] A building decoration material, by weight, comprises 30 parts cement, 36 parts lightweight sand, 10 parts sepiolite fiber, 3 parts methylcellulose, 2 parts calcium formate, 15 parts expanded perlite, and 42 parts water. In preparation, the above raw materials are mixed evenly to obtain the building decoration material.

[0085] Comparative Example 3

[0086] By weight, 100 parts of bisphenol A epoxy resin, 15 parts of talc, 18 parts of acetone, and 1 part of defoamer are mixed evenly to obtain a coating.

[0087] Sepiolite fiber and 8wt% ethylenediamine aqueous solution were mixed at a mass ratio of 1:2 and soaked for 1 hour. Then, the sepiolite fiber was removed and air-dried at 30°C for 30 minutes to obtain pretreated sepiolite fiber.

[0088] The coating and pretreated sepiolite fiber were sprayed onto the sepiolite fiber at a mass ratio of 1:3 and reacted at 60°C for 4 hours to obtain sepiolite fiber loaded with an epoxy resin layer.

[0089] Performance testing

[0090] The materials in each embodiment and comparative example were tested according to JC / T 547-2017, and the results are shown in Table 1.

[0091] Table 1 Performance Test Results

[0092]

[0093]

[0094] As shown in Table 1, compared with Comparative Examples 1-3, the present invention can effectively improve the bonding strength of building decoration materials by loading an epoxy resin layer containing talc particles onto the surface of sepiolite fibers. Furthermore, as shown in Examples 1 and 5-7, by loading phosphate ester compounds onto the surface of lightweight sand, the interaction between these compounds and epoxy resin can further improve the bonding strength of the system and enhance the durability of the building decoration materials.

[0095] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

[0096] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A building decoration material, characterized in that, The raw materials include the following parts by weight: 30-50 parts cement; 20-40 parts lightweight sand; 10-20 parts sepiolite fiber; 1-3 parts lubricant; 1-3 parts early strength agent; 15-25 parts filler; and 30-50 parts water. The sepiolite fiber is loaded with an epoxy resin layer containing hydrophobic particles, which are talc powder with epoxy silane grafted on its surface. The sepiolite fibers are processed as follows: The sepiolite fibers were soaked in an ethylenediamine aqueous solution with a mass concentration of 8wt%-10wt%, and then removed and dried to obtain pretreated sepiolite fibers. An epoxy resin coating containing hydrophobic particles is sprayed onto the surface of pretreated sepiolite fibers and reacted at 60℃-80℃ for 4-5 hours to obtain sepiolite fibers loaded with an epoxy resin layer. The lightweight sand undergoes pretreatment: Light sand is mixed with a weakly alkaline dopamine solution and reacted for 25-30 hours. The light sand is then removed, washed, and dried to obtain polydopamine-coated light sand. A mixture of polydopamine-coated lightweight sand, phosphate ester compounds, and silane coupling agent in an ethanol-water solution at a mass ratio of 1:(2-3):(4-5) was prepared and treated at 70℃-80℃ for 2-3 hours. The treated lightweight sand was then removed, washed, and dried to obtain the treated lightweight sand.

2. The building decoration material according to claim 1, characterized in that, The mass ratio of the sepiolite fiber to the ethylenediamine aqueous solution is 1:(2-3), and the mass ratio of the pretreated sepiolite fiber to the epoxy resin coating is 1:(3-4).

3. The building decoration material according to claim 1, characterized in that, The epoxy resin coating comprises the following raw materials in parts by weight: 100 parts of bisphenol A type epoxy resin, 15-20 parts of talc powder, 18-25 parts of diluent, and 1-3 parts of defoamer.

4. The building decoration material according to claim 1, characterized in that, The talc powder is processed as follows: Talc powder and an ethanol-water solution of epoxysilane with a mass concentration of 3wt%-5wt% were mixed and treated at 70℃-80℃ for 2h-3h, and then dried.

5. The building decoration material according to claim 1, characterized in that, The epoxy silane is at least one of KH-550, KH-560, and KH-570.

6. The building decoration material according to claim 1, characterized in that, The phosphate ester compound is at least one of dibutyl phosphate, tributyl phosphate, and monobutyl phosphate.

7. The building decoration material according to claim 1, characterized in that, The silane coupling agent is at least one of vinyltrimethoxysilane and vinyltriethoxysilane.

8. A method for preparing a building decoration material according to any one of claims 1-7, characterized in that, According to the formula, cement, lightweight sand, sepiolite fiber, lubricant, early strength agent, filler and water are mixed evenly to obtain building decoration materials.

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