Fireproof environment-friendly decorative plate containing antibacterial coating

Abstract

The invention discloses a fireproof environment-friendly decorative plate containing an antibacterial coating, and relates to the technical field of decorative plates. (2) a multi-layer composite decorative layer; the core layer is formed by mixing magnesium oxide, magnesium chloride, volcanic ash, bentonite and a cellulose reinforcing agent in a dry mode, mixing the mixture with a magnesium chloride solution to form slurry, and conducting continuous rolling forming and high-temperature curing; the antibacterial coating is formed by mixing a waterborne polyurethane dispersion and a nano-hydroxyapatite-silver copper ion composite antibacterial agent according to the mass ratio of 100: 3 and carrying out low-temperature plasma surface activation and curing. Through the volcanic ash-MgO secondary hydration composite core layer, a compact C-S-H network is generated, the fire-resistant strength and toughness are improved, the problem that a magnesium oxide board is insufficient in strength and durability is solved, the bending strength and the impact toughness are improved, and the B1 fireproof grade is achieved.

Description

Technical Field

[0001] The invention relates to the technical field of decorative panels, in particular to a fireproof and environmentally friendly decorative panel containing an antibacterial coating. Background Art

[0002] As the construction industry's comprehensive demands for safety, environmental protection, and health continue to rise, traditional glass-magnesium panels and ordinary decorative panels often suffer from issues such as insufficient fire resistance, bacterial growth on their surfaces, long production cycles, and high costs. On the one hand, fire safety regulations have placed higher demands on the combustion ratings of building materials; on the other hand, public spaces are seeing a significant increase in interest in antimicrobial materials. Furthermore, environmental regulations are becoming increasingly stringent regarding VOC and formaldehyde emissions.

[0003] Patent CN105601247B discloses a fireproof, decorative and heat-insulating outdoor environmentally friendly composite decorative panel and its manufacturing method. The above patent addresses the gaps or limitations of existing market products in terms of performance. Through the research and development of material formulas and improvements in production and processing methods, it truly realizes a composite decorative panel for long-term outdoor use that is environmentally friendly, fireproof, water-like, has heat-insulating functions, and has exquisite shapes, realistic colors, and simple installation. The panel and its manufacturing method are simple.

[0004] Although the above patent is environmentally friendly, fireproof, water-like, and has thermal insulation functions, its fire resistance, surface strength and toughness still need to be improved.

[0005] To this end, the present application proposes a fireproof and environmentally friendly decorative board containing an antibacterial coating that can generate a dense CSH network and improve fire resistance and toughness. Summary of the Invention

[0006] The purpose of the present invention is to provide a fireproof and environmentally friendly decorative panel containing an antibacterial coating to solve the technical problems raised in the above background technology, such as insufficient fireproof performance, easy growth of bacteria on the surface, long production cycle and high cost.

[0007] To achieve the above object, the present invention provides the following technical solution: a fireproof and environmentally friendly decorative panel containing an antibacterial coating, the decorative panel comprising, in order:

[0008] (1) Core layer;

[0009] (2) Multi-layer composite decorative layer;

[0010] (3) Antibacterial coating

[0011] The antibacterial coating is composed of three parts: the core layer is made by dry-mixing magnesium oxide, magnesium chloride, volcanic ash, bentonite and cellulose reinforcing agent, and then preparing a slurry with magnesium chloride solution, which is then continuously rolled and cured at high temperature; the antibacterial coating is made by mixing an aqueous polyurethane dispersion and a nano-hydroxyapatite-silver-copper ion composite antibacterial agent in a mass ratio of 100:3, and then curing by low-temperature plasma surface activation.

[0012] Preferably, the mass ratio of the components in the core layer is:

[0013] Magnesium oxide:magnesium chloride:activated volcanic ash:bentonite:cellulose enhancer = 1:0.3:0.2:0.05:0.02;

[0014] The magnesium chloride is a liquid saturated solution, and the cellulose enhancer is sodium carboxymethyl cellulose, with a content of 0.02 parts by mass, which is used to improve the rheological properties of the sauce and the fiber network structure after drying.

[0015] Preferably, the continuous roll forming process parameters are:

[0016] The roller diameter of the roller press is 300mm and the roller material is alloy steel;

[0017] Roller pressure 3MPa;

[0018] The roller pressing temperature is controlled at 25±2℃;

[0019] Roller gap 2mm, laying speed 0.8m / min;

[0020] The slab is formed into a width of 1220mm and a thickness of 8-12mm, and is produced continuously in a single forming process.

[0021] Preferably, the multi-layer composite decorative layer comprises:

[0022] Water-based PU adhesive;

[0023] printed wood grain paper;

[0024] Hot pressing is carried out at 120℃ and pressure 0.8MPa for 10min. After pressing, the adhesion reaches level 5 after tensile test, and the water blister resistance is ≥72h without delamination.

[0025] Preferably, the preparation method of the nano-hydroxyapatite-silver-copper ion composite antibacterial agent comprises:

[0026] Dispersing hydroxyapatite nanopowder in deionized water;

[0027] Ag(NO3)2 and Cu(NO3)2 were added to the suspension respectively with a molar ratio of HAP:Ag:Cu=1:0.02:0.01;

[0028] Slowly add NaOH dropwise until pH = 10, and stir to coprecipitate for 2 h;

[0029] Composite powders were obtained by centrifugation, washing and vacuum drying, with Ag and Cu loadings of 1.8% and 0.9%, respectively.

[0030] Preferably, the spraying and curing process of the antibacterial coating is as follows:

[0031] Primer spraying: thickness 30±2um, spraying pressure 0.4MPa, drying temperature 60℃, drying time 4h;

[0032] Topcoat spraying: thickness 15±1um, spraying pressure 0.4MPa, drying temperature 60℃, drying time 4h;

[0033] Surface plasma activation: power 100 W, frequency 13.56 MHz, argon flow rate 20 sccm, treatment for 5 min to enhance the chemical bonding between the coating and the substrate;

[0034] Overall curing: reflux curing at 80℃ for 2h.

[0035] Preferably, the high temperature tunnel furnace curing process parameters of the high temperature curing are:

[0036] Temperature 80±2℃, relative humidity 70±5℃;

[0037] Conveyor belt speed 0.5m / min, total curing length 30m;

[0038] The curing time is 8 h to ensure that magnesium oxide, magnesium chloride and active pozzolan are fully hydrated and react to form a dense CSH gel network.

[0039] Preferably, the active volcanic ash is a powder with a SiO2 content ≥60%, an Al2O3 content of 10-15%, and Fe2O3 <6%, and a particle size of <45um. It has been calcined at 600°C for 2h to activate Si-Al sites, promote secondary hydration with the Mg system, and enhance the structural density and durability of the substrate.

[0040] Preferably, the overall production line of decorative panels adopts a four-stage continuous process:

[0041] Automatic batching and mixing unit for raw materials;

[0042] Roll forming unit;

[0043] Tunnel oven curing unit;

[0044] Surface lamination and spraying unit with UV pre-curing and plasma activation.

[0045] Preferably, the decorative board is subjected to the following test performance indicators:

[0046] Fire resistance performance is in accordance with GB / T 20284-2006 B1 level;

[0047] Flexural strength ≥18MPa;

[0048] Impact strength ≥5kJ / m 2 ;

[0049] Antibacterial performance: The antibacterial rate against Staphylococcus aureus and Escherichia coli is ≥99.9%, and the effective period in continuous testing is ≥12 months;

[0050] Environmental performance: VOC emission <0.05g / m 2 h, free formaldehyde <0.05 mg / m 3 .

[0051] Compared with the prior art, the present invention has the following beneficial effects:

[0052] 1. The present invention uses a volcanic ash-MgO secondary hydration composite core layer to generate a dense CSH network, improve fire resistance and toughness, solve the problem of insufficient strength and durability of glass magnesium board, improve bending strength and impact toughness, and achieve B1 fire protection grade;

[0053] 2. This invention uses continuous roller pressing and tunnel furnace curing technology to achieve efficient forming and curing, shorten the production cycle, improve production capacity, solve the problem of long curing cycle and low production capacity of traditional methods, increase output and reduce costs;

[0054] 3. The present invention uses a nano-hydroxyapatite and silver-copper ion antibacterial composite coating to achieve sustained release of silver and copper ions for long-term antibacterial effect, solving the problems of short lifespan and weakened effect of existing organic antibacterial coatings, improving the antibacterial rate, and being healthy and environmentally friendly.

[0055] 4. The present invention realizes diversified decorative effects through hot pressing and laminating of multiple decorative layers, enhances surface wear resistance and water resistance, solves the problem of easy degumming of the decorative layer and lack of diversified options, improves adhesion and water resistance and meets personalized needs. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] Figure 1 It is a schematic diagram of the structural layer of the decorative board of the present invention. DETAILED DESCRIPTION

[0057] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0058] Example 1

[0059] See also Figure 1 A fireproof and environmentally friendly decorative board containing an antibacterial coating is prepared by standard preparation steps:

[0060] Raw material ratio: MgO (activated magnesium oxide, D95≤10um): 100 parts; MgCl2·6H2O (32% saturated solution): 30 parts; volcanic ash (SiO2≥60%, D95≤45um): 20 parts; bentonite (Na-type, water absorption ≥120%): 5 parts; sodium carboxymethyl cellulose (CMC, rheology modifier): 2 parts;

[0061] Slurry preparation: MgO, volcanic ash, and bentonite were mixed in a V-type dry mixer according to the proportions for 3 minutes. MgCl2 solution was slowly added and stirred at high speed (300 rpm) with a ribbon blender for 5 minutes. CMC was added and dispersed evenly. The slurry viscosity was adjusted to 10,000 mPa·s (Brookfield, 2 rpm).

[0062] Roll forming: Equipment: Double-roll press with ψ300mm carbon steel rollers; Parameters: pressure 3MPa, gap 2mm, temperature 25°C, speed 0.8m / min; slab size 1220mm×8mm was obtained;

[0063] Tunnel oven curing: Equipment: 30m long tunnel oven; Parameters: 80±2℃, RH70±5%, speed 0.5m / min, curing time 8h;

[0064] Surface bonding: Adhesive: Water-based PU (solid content 48%, NCO:OH=1:1.2); Printing paper: 80g / m 2 Wood grain paper; hot pressing: 120℃, 0.8MPa, 10min;

[0065] Antibacterial coating spraying: Primer: 100 parts PU dispersion + 3 parts HAP / Ag / Cu powder, thickness 30 μm, dried at 60°C for 4 hours; Topcoat: same as primer, thickness 15 μm; Plasma activation: Ar gas 20 sccm, 100 W, 13.56 MHz, 5 minutes; Reflow curing: 80°C, 2 hours;

[0066] The overall production line of decorative panels adopts a four-stage continuous process:

[0067] Automatic batching and mixing unit for raw materials;

[0068] Roll forming unit;

[0069] Tunnel oven curing unit;

[0070] Surface lamination and spraying unit, including UV pre-curing and plasma activation;

[0071] The specific preparation steps are as follows: accurately measure MgO, MgCl2 solution, volcanic ash, bentonite and cellulose reinforcement, carry out V-type dry mixing and high-speed wet mixing, and adjust the slurry viscosity to 10,000 mPa·s; pass the slurry through a ψ300mm double-roll press to form a slab at a pressure of 3 MPa, a gap of 2 mm, and a speed of 0.8 m / min; then enter the tunnel oven at 80°C and 70% RH for tunnel curing for 8 hours; roll PU glue on the surface of the cured core board, adhere water-based wood grain paper / non-woven fabric / metal film, and hot press at 120°C, 0.8 MPa, and 10 minutes to achieve level 5 adhesion at the interface; spray primer (30 μm) and topcoat (15 μm), activate with low-temperature plasma (100W, 13.56 MHz, 5 minutes), and reflux cure at 80°C for 2 hours to complete the final antibacterial protective layer construction.

[0072] Example 2

[0073] See also Figure 1 , a fireproof and environmentally friendly decorative board containing an antibacterial coating. Based on Example 1, in order to further enhance the mechanical properties, the formula and process are adjusted as follows:

[0074] Formula adjustment: volcanic ash increased to 25 parts, MgCl2 reduced to 28 parts;

[0075] Add microfiber reinforcement: Add additional polypropylene fibers (6 mm in length, 0.5 parts in content) to the slurry to improve impact resistance;

[0076] Rolling parameters: pressure increased to 3.3 MPa, gap 1.8 mm, and other parameters remained unchanged;

[0077] The overall production line of decorative panels adopts a four-stage continuous process:

[0078] Automatic batching and mixing unit for raw materials;

[0079] Roll forming unit;

[0080] Tunnel oven curing unit;

[0081] Surface lamination and spraying unit, including UV pre-curing and plasma activation;

[0082] The specific preparation steps are as follows: accurately measure MgO, MgCl2 solution, volcanic ash, bentonite and cellulose reinforcement, carry out V-type dry mixing and high-speed wet mixing, and adjust the slurry viscosity to 10,000 mPa·s; pass the slurry through a ψ300mm double-roll press at a pressure of 3.3 MPa, a gap of 1.8 mm, and a speed of 0.8 m / min to form a slab; then enter the tunnel oven at 80°C and 70% RH for tunnel curing for 8 hours; roll PU glue on the surface of the cured core board, adhere water-based wood grain paper / non-woven fabric / metal film, and hot press at 120°C, 0.8 MPa, and 10 minutes to achieve level 5 adhesion at the interface; spray primer (30 μm) and topcoat (15 μm), activate with low-temperature plasma (100W, 13.56 MHz, 5 minutes), and reflux cure at 80°C for 2 hours to complete the final antibacterial protective layer construction.

[0083] Example 3

[0084] See also Figure 1 , a fireproof and environmentally friendly decorative board containing an antibacterial coating, based on Example 1, shortens the tunnel furnace curing time for the demand for rapid delivery:

[0085] Minor adjustments to the formula: add 1 part of calcium chloride to the MgCl2 solution to accelerate the hydration reaction rate;

[0086] Tunnel oven process: temperature increased to 90°C, relative humidity 65%; speed 1.0m / min, total curing time shortened to 6h;

[0087] The overall production line of decorative panels adopts a four-stage continuous process:

[0088] Automatic batching and mixing unit for raw materials;

[0089] Roll forming unit;

[0090] Tunnel oven curing unit;

[0091] Surface lamination and spraying unit, including UV pre-curing and plasma activation;

[0092] The specific preparation steps are as follows: accurately measure MgO, MgCl2 solution, volcanic ash, bentonite and cellulose reinforcement, carry out V-type dry mixing and high-speed wet mixing, and adjust the slurry viscosity to 10,000 mPa·s; pass the slurry through a ψ300mm double-roll press to form a slab at a pressure of 3 MPa, a gap of 2 mm, and a speed of 0.8 m / min; then enter the tunnel oven at 90°C and 65% RH for tunnel curing for 6 hours; roll PU glue on the surface of the cured core board, adhere water-based wood grain paper / non-woven fabric / metal film, and hot press at 120°C, 0.8 MPa, and 10 minutes to achieve level 5 adhesion at the interface; spray primer (30 μm) and topcoat (15 μm), activate with low-temperature plasma (100W, 13.56 MHz, 5 minutes), and reflux cure at 80°C for 2 hours to complete the final antibacterial protective layer construction.

[0093] Example 4

[0094] See also Figure 1 , a fireproof and environmentally friendly decorative board with an antibacterial coating, based on Example 1, replaces some inorganic raw materials and optimizes the process to meet more stringent environmental protection requirements:

[0095] Raw material replacement: some MgCl2 is replaced by industrial waste seawater (containing Mg 2+ About 3%) replaced 20 parts to reduce costs and carbon footprint; introduced 10 parts of silica fume (carbide slag powder, SiO2 ≥ 85%, D90 ≤ 10um) for synergistic activation;

[0096] Slurry and molding: Keep the roller pressing parameters the same as in Example 1, and introduce closed-circuit condensation recovery during tunnel furnace curing, saving 10% energy;

[0097] The overall production line of decorative panels adopts a four-stage continuous process:

[0098] Automatic batching and mixing unit for raw materials;

[0099] Roll forming unit;

[0100] Tunnel oven curing unit;

[0101] Surface lamination and spraying unit, including UV pre-curing and plasma activation;

[0102] The specific preparation steps are as follows: accurately measure MgO, MgCl2 solution, volcanic ash, bentonite and cellulose reinforcement, carry out V-type dry mixing and high-speed wet mixing, and adjust the slurry viscosity to 10,000 mPa·s; pass the slurry through a ψ300mm double-roll press to form a slab at a pressure of 3 MPa, a gap of 2 mm, and a speed of 0.8 m / min; then enter the tunnel oven at 80°C and 70% RH for tunnel curing for 8 hours; roll PU glue on the surface of the cured core board, adhere water-based wood grain paper / non-woven fabric / metal film, and hot press at 120°C, 0.8 MPa, and 10 minutes to achieve level 5 adhesion at the interface; spray primer (30 μm) and topcoat (15 μm), activate with low-temperature plasma (100W, 13.56 MHz, 5 minutes), and reflux cure at 80°C for 2 hours to complete the final antibacterial protective layer construction.

[0103] Example 5

[0104] See also Figure 1 A fireproof and environmentally friendly decorative board with an antibacterial coating, based on Example 1, adopts a variety of finishes for different decorative effects:

[0105] Finishing material: A: 80g / m 2 Wood grain paper; B: 150g / m 2 Non-woven leather paper, wear-resistant coating; C: 100g / m 2 Metal brushed film (PET substrate + aluminum layer);

[0106] Lamination process: Due to the different thicknesses of non-woven fabric and metal film, the hot pressing is adjusted to: temperature 130°C, pressure 1.0 MPa, time 12 minutes;

[0107] Antibacterial coating adaptability: For metal film finishes, add 0.5 parts of leveling agent to the topcoat to ensure coating certification;

[0108] The overall production line of decorative panels adopts a four-stage continuous process:

[0109] Automatic batching and mixing unit for raw materials;

[0110] Roll forming unit;

[0111] Tunnel oven curing unit;

[0112] Surface lamination and spraying unit, including UV pre-curing and plasma activation;

[0113] The specific preparation steps are as follows: accurately measure MgO, MgCl2 solution, volcanic ash, bentonite and cellulose reinforcement, carry out V-type dry mixing and high-speed wet mixing, and adjust the slurry viscosity to 10,000 mPa·s; pass the slurry through a ψ300mm double-roll press at a pressure of 3 MPa, a gap of 2 mm, and a speed of 0.8 m / min to form a slab; then enter the tunnel oven at 80°C and 70% RH for tunnel curing for 8 hours; roll PU glue on the surface of the cured core board, adhere water-based wood grain paper / non-woven fabric / metal film, and hot press at 130°C, 1.0 MPa, and 12 minutes to achieve level 5 adhesion at the interface; spray primer (30 μm) and topcoat (15 μm), low-temperature plasma activation (100W, 13.56 MHz, 5 minutes), and reflux curing at 80°C for 2 hours to complete the final antibacterial protective layer construction.

[0114] Performance test of the above decorative panels:

[0115] Performance tests were performed on the decorative panels prepared in Examples 1-5 to facilitate industrialization and subsequent certification:

[0116] 1. Fire performance test

[0117] Test standard: GB / T 20284-2006 "Classification of Combustion Performance of Building Materials and Products";

[0118] Sample preparation: Cut at least 3 decorative board samples with a size of 150mm × 50mm × test board thickness;

[0119] Equipment: Horizontal combustion test device (including adjustable natural gas / liquefied gas flame, flue gas extraction system, flame height and burning time recording device);

[0120] condition:

[0121] The flame inclination angle is 45° and the flame height in the burner is 20mm;

[0122] Ambient temperature 23±2℃, relative humidity 20±5%;

[0123] method:

[0124] First, dry the sample under standard environmental conditions for 4 hours;

[0125] Fix the sample on the combustion table and extinguish the flame after 30 seconds;

[0126] Record the total combustion length L and afterburning time t;

[0127] Calculation of combustion level: B1 level should meet L≤150mm and t≤30s;

[0128] Evaluation: All samples meet the B1 level requirements.

[0129] 2. Bending strength test

[0130] Test standard: GB / T 17657-2013 "Test methods for physical and chemical properties of wood-based panels and veneered wood-based panels" - three-point bending method;

[0131] Specimen: 200mm long × 50mm wide × (8-12)mm thick, at least 5 pieces;

[0132] Equipment: Electronic universal testing machine (load adjustable to 50kN, deformation speed adjustable);

[0133] condition:

[0134] Span L = 160mm;

[0135] Loading speed 5mm / min;

[0136] Ambient temperature 23±2℃, relative humidity 50±5%;

[0137] method:

[0138] Place the specimen horizontally on two supporting points;

[0139] The central loading head presses down vertically and records the load-deformation curve;

[0140] Take the maximum load before fracture F max ;

[0141] Calculate the bending strength σ = (3F maxL ) / (2bd 2 ), where b is the width and d is the thickness;

[0142] Evaluation: σ≥18MPa.

[0143] 3. Impact strength test

[0144] Test standard: GB / T 17657-2013--Pendulum impact method;

[0145] Specimen: 200mm long × 50mm wide × 8-12mm thick, at least 5 pieces;

[0146] Equipment: Pendulum impact testing machine (drop weight 5kg, measurable energy up to 10kJ);

[0147] condition:

[0148] Ambient temperature 23±2℃, relative humidity 50±5%;

[0149] method:

[0150] Place the sample on the pendulum support frame;

[0151] Release the pendulum from a specified height and record the energy absorption value E at impact failure;

[0152] Impact strength K=E / A, where A is the impact area of ​​the sample (50mm×thickness);

[0153] Evaluation: K≥5kJ / m 2 .

[0154] 4. Antibacterial performance test

[0155] Test standard: ISO 22196 "Determination of antimicrobial activity and effectiveness on plastics and other non-porous surfaces";

[0156] Test bacteria: Staphylococcus aureus (ATCC 6538) and Escherichia coli (ATCC 8739);

[0157] Sample: Cut into 50mm×50mm plates with the surface coating facing up, at least 3 pieces per strain;

[0158] Equipment and reagents: incubator (35 ± 1°C), nutrient agar, PBS buffer;

[0159] method:

[0160] Inoculate 100 μL of bacterial suspension (concentration of approximately 105 CFU / mL) on the surface of each specimen and cover with a sterile coverslip to prevent diffusion;

[0161] Keep warm at 35℃ for 24h;

[0162] Elute the bacteria with PBS buffer and count the number of viable bacteria on the plate. A ;

[0163] The colony count N was measured against the plate without antibacterial coating. C ;

[0164] Calculate the inhibition rate: R (%) = [N C -N A / N C ]×100%;

[0165] Evaluation: R ≥ 99.9%, and after accelerated aging for 12 months at 50°C and 90% relative humidity, the antibacterial rate is still ≥ 98%.

[0166] 5. VOC emission test

[0167] Test standard: ISO 16000-9 "Building materials - Determination of volatile organic compound emissions - Part 9: Chamber method";

[0168] Sample: 400mm×400mm plate, at least 2 pieces;

[0169] Equipment: Environmental test chamber (volume 1m 3 , controllable temperature 23±2℃, humidity 50±5%, ventilation frequency 0.5h -1 );

[0170] method:

[0171] Place the sample horizontally in the chamber and start the test after the ventilation is adjusted to stable;

[0172] Sampling was continued for 8 h, and gas-phase VOCs were collected using Tenax adsorption tubes;

[0173] Thermal desorption-gas chromatography / mass spectrometry (GC / MS) was used to quantify total volatile organic compounds (TVOCs);

[0174] Evaluation: TVOC≤0.05g / m 2 ·h.

[0175] 6. Formaldehyde emission test

[0176] Test standard: EN 717-1 "Determination of formaldehyde emission from wood-based panels - Part 1: Chamber method"

[0177] Sample: Same as VOC test, at least 2 pieces;

[0178] Equipment: Same as ISO 16000-9 chamber;

[0179] method:

[0180] Chamber conditions: 23±2℃, humidity 50±5%, ventilation rate 0.5h -1 ;

[0181] Sampling time: 1, 3, and 7 days respectively;

[0182] Gas chromatography-high-performance liquid chromatography (HPLC) to quantify formaldehyde after DNPH derivatization;

[0183] Evaluation: Release ≤0.05mg / m 3 (Measured on the 3rd day).

[0184] The final results of the performance tests of Examples 1-5 are summarized in Table 1 Performance Test Results.

[0185] All indicators are measured according to the above test methods:

[0186] Table 1 Performance test results

[0187] Example Fire rating σ K Antibacterial rate TVOC 1 B1 18.3 5.0 99.9 / 99.9 0.04 2 B1 20.1 6.2 99.9 / 99.9 0.04 3 B1 18.0 5.0 99.9 / 99.9 0.05 4 B1 17.2 5.1 99.9 / 99.9 0.03 Wood grain paper 5 B1 18.5 5.1 99.9 / 99.9 0.04 Non-woven fabric 5 B1 17.8 5.0 99.9 / 99.9 0.04 Metal film 5 B1 17.0 4.8 99.9 / 99.9 0.04

[0188] illustrate:

[0189] All embodiments meet the fire protection B1 level requirements;

[0190] The antibacterial rate reached 99.9% against both Staphylococcus aureus and Escherichia coli, and remained ≥98% after 12 months of accelerated aging at 50% / 90% RH (initial values ​​shown in the table);

[0191] VOC and formaldehyde emissions are both in compliance with E1 level;

[0192] Example 2 significantly improves mechanical properties through microfiber reinforcement and formulation optimization;

[0193] Example 3 sacrifices a small amount of mechanical properties in exchange for rapid curing;

[0194] Example 4 reduces VOC emissions and saves energy;

[0195] Example 5 demonstrates the comprehensive performance under different finishes.

[0196] Working Principle: This decorative board uses a MgO-MgCl2 system as its base, incorporating highly active volcanic ash and bentonite. A dense CSH network is generated through a hydration reaction, creating a porous-dense microstructure. This allows the board to maintain shape stability even under high-temperature conditions, meeting B1-class fire protection requirements. Cellulose reinforcement and optional microfibers further enhance its flexural and impact strength.

[0197] After the core layer is fully cured, the decorative layer, such as wood grain paper, non-woven fabric or metal film, is tightly bonded to the substrate using water-based PU adhesive. Heat pressing is then used to evenly bond the interface, resulting in excellent surface smoothness, water resistance and abrasion resistance. This multi-layer composite method not only meets aesthetic needs, but also leverages the mechanical and chemical stability of the decorative layer itself, improving the service life and decorative diversity of the board.

[0198] The decorative layer is coated with a frosted, water-based polyurethane antimicrobial coating containing a nano-hydroxyapatite / silver-copper ion composite antimicrobial agent dispersed via low-temperature plasma activation, forming a micro-nanoscale porous network. The sustained release of silver and copper ions, combined with the adsorption of the hydroxyapatite carrier, disrupts bacterial cell membranes and inhibits their metabolism, ensuring a highly effective and long-lasting antibacterial effect exceeding 99.9%, and maintaining an antibacterial effect of ≥98% even in extreme aging conditions.

[0199] 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 embodied 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 illustrative and non-restrictive, and the scope of the invention is defined by the appended claims, not the foregoing description, and all variations within the meaning and range of equivalents of the claims are intended to be included therein. Any reference sign in a claim should not be construed as limiting the claim to which it relates.

Claims

1. A fireproof and environmentally friendly decorative panel with an antibacterial coating, characterized by: The decorative panels are composed in order: (1) Core layer; (2) Multi-layer composite decorative layer; (3) Antibacterial coating The antibacterial coating is composed of three parts: the core layer is made by dry-mixing magnesium oxide, magnesium chloride, volcanic ash, bentonite and cellulose reinforcing agent, and then preparing a slurry with magnesium chloride solution, which is then continuously rolled and cured at high temperature; the antibacterial coating is made by mixing an aqueous polyurethane dispersion and a nano-hydroxyapatite-silver-copper ion composite antibacterial agent in a mass ratio of 100:3, and then curing by low-temperature plasma surface activation.

2. The fireproof and environmentally friendly decorative board with antibacterial coating according to claim 1, characterized in that: The mass ratio of each component in the core layer is: Magnesium oxide:magnesium chloride:activated volcanic ash:bentonite:cellulose enhancer = 1:0.3:0.2:0.05:0.02; The magnesium chloride is a liquid saturated solution, and the cellulose enhancer is sodium carboxymethyl cellulose, with a content of 0.02 parts by mass, which is used to improve the rheological properties of the sauce and the fiber network structure after drying.

3. The fireproof and environmentally friendly decorative board with antibacterial coating according to claim 1, characterized in that: The continuous roll forming process parameters are: The roller diameter of the roller press is 300mm and the roller material is alloy steel; Roller pressure 3MPa; The roller pressing temperature is controlled at 25±2℃; Roller gap 2mm, laying speed 0.8m / min; The slab is formed into a width of 1220mm and a thickness of 8-12mm, and is produced continuously in a single forming process.

4. The fireproof and environmentally friendly decorative board with antibacterial coating according to claim 1, characterized in that: The multi-layer composite decorative layer comprises: Water-based PU adhesive; printed wood grain paper; Hot pressing is carried out at 120℃ and pressure 0.8MPa for 10min. After pressing, the adhesion reaches level 5 after tensile test, and the water blister resistance is ≥72h without delamination.

5. The fireproof and environmentally friendly decorative board with antibacterial coating according to claim 1, characterized in that: The preparation method of the nano-hydroxyapatite-silver-copper ion composite antibacterial agent comprises: Dispersing hydroxyapatite nanopowder in deionized water; Ag(NO3)2 and Cu(NO3)2 were added to the suspension respectively with a molar ratio of HAP:Ag:Cu=1:0.02:0.01; Slowly add NaOH dropwise until pH = 10, and stir to coprecipitate for 2 h; Composite powders were obtained by centrifugation, washing and vacuum drying, with Ag and Cu loadings of 1.8% and 0.9%, respectively.

6. The fireproof and environmentally friendly decorative board with antibacterial coating according to claim 1, characterized in that: The spraying and curing process of the antibacterial coating is as follows: Primer spraying: thickness 30±2um, spraying pressure 0.4MPa, drying temperature 60℃, drying time 4h; Topcoat spraying: thickness 15±1um, spraying pressure 0.4MPa, drying temperature 60℃, drying time 4h; Surface plasma activation: power 100 W, frequency 13.56 MHz, argon flow rate 20 sccm, treatment for 5 min to enhance the chemical bonding between the coating and the substrate; Overall curing: reflux curing at 80℃ for 2h.

7. The fireproof and environmentally friendly decorative board with antibacterial coating according to claim 1, characterized in that: The high temperature tunnel furnace curing process parameters for high temperature curing are: Temperature 80±2℃, relative humidity 70±5℃; Conveyor belt speed 0.5m / min, total curing length 30m; The curing time is 8 h to ensure that magnesium oxide, magnesium chloride and active pozzolan are fully hydrated and react to form a dense CSH gel network.

8. The fireproof and environmentally friendly decorative board with antibacterial coating according to claim 7, characterized in that: The active volcanic ash is a powder with a SiO2 content of ≥60%, an Al2O3 content of 10-15%, and Fe2O3 of <6%, and a particle size of <45um. It has been calcined at 600°C for 2h to activate Si-Al sites, promote secondary hydration with the Mg system, and enhance the structural density and durability of the substrate.

9. The fireproof and environmentally friendly decorative board with antibacterial coating according to claim 1, characterized in that: The overall production line of decorative panels adopts a four-stage continuous process: Automatic batching and mixing unit for raw materials; Roll forming unit; Tunnel oven curing unit; Surface lamination and spraying unit with UV pre-curing and plasma activation.

10. The fireproof and environmentally friendly decorative board with antibacterial coating according to claim 1, characterized in that: The performance indicators of the decorative board obtained by the following tests: Fire resistance performance is in accordance with GB / T 20284-2006 B1 level; Flexural strength ≥18MPa; Impact strength ≥5kJ / m 2 ; Antibacterial performance: The antibacterial rate against Staphylococcus aureus and Escherichia coli is ≥99.9%, and the effective period in continuous testing is ≥12 months; Environmental performance: VOC emission <0.05g / m 2 h, free formaldehyde <0.05 mg / m 3 .

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