A non-toxic and environment-friendly novel wall material and a preparation method thereof

Abstract

This invention relates to the field of natural green coating technology, specifically to a non-toxic and environmentally friendly wall material and its preparation method. The wall material, prepared by mixing quicklime (10% quartz sand): glutinous rice flour: white sugar: cotton in a weight ratio (w / w) of (88.7-93.5):(3-10):(2-5):(0.3-0.8), basically meets all standard requirements. Further color matching with an appropriate amount of volcanic ash allows for the selection of various colors. This invention utilizes a nano-porous structure to prepare the wall material, which possesses numerous advantages including strong weather resistance and durability, water resistance, breathability and moisture resistance, antibacterial and mildew resistance, super strong adhesion, and ease of application. It is suitable for sensitive groups such as children, pregnant women, and the elderly. This invention redefines the standards for healthy living in the new era.

Description

Technical Field

[0001] This invention relates to the field of natural green coating technology, specifically to a non-toxic and environmentally friendly wall material and its preparation method. Background Technology

[0002] As people's living standards improve, their environmental awareness is also constantly increasing. A survey by indoor environmental experts shows that modern people spend an average of 90% of their time indoors, and 65% of that time at home. Statistics show that nearly half of the world's population is exposed to indoor air pollution, which has caused 35.7% of respiratory diseases, 25% of chronic lung diseases, and 15% of tracheitis, bronchitis, and lung cancer. Therefore, modern people's requirements for decorative materials are not only aesthetically pleasing and practical, but also include new and higher demands for safety and environmental protection. 99.99% of wall materials on the market, such as putty powder, diatomaceous earth, artistic paint, and latex paint, will experience problems such as efflorescence, blistering, powdering, mold, water seepage, or peeling. Therefore, the market urgently needs to develop a new type of wall material with multiple advantages, including strong weather resistance and durability, water resistance, breathability and moisture resistance, antibacterial and mildew resistance, super strong adhesion, and easy construction, suitable for sensitive groups such as children, pregnant women, and the elderly. Summary of the Invention

[0003] In view of the problems in the prior art, the present invention aims to provide a new type of non-toxic and environmentally friendly wall material and its preparation method.

[0004] A new type of non-toxic and environmentally friendly wall material: by weight ratio (w / w), quicklime containing 10% quartz sand: glutinous rice flour: sugar: natural fiber = (88.7-93.5):(3-10):(2-5):(0.3-0.8), sheared and mixed evenly; the sugar is one or both of white sugar and brown sugar; the natural fiber is one or both of hemp fiber and cotton fiber.

[0005] The sugar is pulverized at low temperature (0°C) and high speed to 120-150 mesh; the natural fiber is pulverized to 100-150 mesh.

[0006] The natural fiber is cotton. The sugar is white sugar.

[0007] Preferably, the ratio of quicklime containing 10% quartz sand to glutinous rice flour to sugar to natural fiber is 91.5:5:5:0.5 by mass ratio (W / W).

[0008] Quicklime and water are mixed and reacted at a mass ratio of 5:2. Quartz sand of 10% of the weight of quicklime is dispersed and added. After cooling, the mixture is stirred appropriately and dried to make the moisture content less than 3%, thus obtaining hydrated lime containing 10% quartz sand. The quartz sand is then crushed to 60-100 mesh.

[0009] Preparation of glutinous rice flour: Soak glutinous rice in water for 3-6 hours, steam over high heat for 20-30 minutes, and then grind at low temperature (0℃) and high speed to 100-150 mesh glutinous rice flour.

[0010] Furthermore, by adding appropriate proportions of volcanic ash, wall materials of different colors can be created.

[0011] A method for preparing a novel, non-toxic, and environmentally friendly wall material: Weigh and prepare the materials according to the above-described formula. Add the pre-treated quicklime containing quartz sand, glutinous rice flour, cotton flour, and white sugar in the prescribed amounts sequentially to a mixing container. Mix thoroughly using a high-speed shearing method. The high-speed shearing method involves a stirring paddle speed of 100 rpm and a cutter speed of 800 rpm, mixing for 5-8 minutes. The sequential addition ensures more uniform mixing of the materials.

[0012] Further, add an appropriate proportion of volcanic ash and shear-mix to achieve the desired wall material color; the shearing parameters are: paddle speed 100 rpm, cutter speed 800 rpm, mixing for 3 minutes.

[0013] Technical effects of the present invention:

[0014] (1) Natural and green, with no harmful chemical additives; (2) Significant antibacterial effect, not easy to mold; (3) Better adhesion, flexibility, water resistance and other properties. Attached Figure Description

[0015] Figure 1 The results of the performance parameters of the wall material of this invention were tested according to JG / T 298-2010;

[0016] Figure 2-1 , Figure 2-2 , Figure 2-3 , Figure 2-4 , Figure 2-5 The wall material of this invention was tested according to JG / T 298-2010;

[0017] Figure 3 The wall material of this invention was tested according to GB8624-2012.

[0018] Figure 4 The wall material of this invention was tested according to GB / T21866-2008;

[0019] Figure 5 The wall material of this invention was tested according to GB / T1741-2020;

[0020] Figure 6 The wall material of this invention was tested according to GB 6566-2010;

[0021] Figure 7 shows the test results of the wall material of the present invention according to GB / T34676-2017;

[0022] Figure 8 A comparison of the technical effects and advantages of the wall materials of the present invention: Quanshengtang Ancient Method Pure Source Lime is the wall material described in the present invention. Detailed Implementation

[0023] I. Formulation Screening of a New Type of Non-toxic and Environmentally Friendly Wall Material

[0024] 99.99% of wall materials on the market, such as putty powder, diatomaceous earth, artistic paint, and latex paint, will experience problems such as efflorescence, blistering, powdering, mold, water seepage, or peeling. Environmentally friendly does not equal non-toxic; there is an urgent market demand for developing truly non-toxic and safe new wall materials.

[0025] Scientists have discovered that glutinous rice accounts for 15%-20% of the mortar used in the Great Wall project. The amylopectin (95%-100%) in the glutinous rice gelatinizes upon heating, acting like natural glue to firmly bind the lime particles. This organic-inorganic composite material (i.e., traditional lime-glutinous rice mortar) increases the mortar's strength by more than 50% compared to pure lime. This invention is an improved and optimized development based on the traditional lime-glutinous rice mortar process, eliminating toxic chemicals and combining natural lime with five natural materials: white sugar, glutinous rice flour, quartz sand, and cotton. Through precise scientific proportions, it creates a truly natural, non-toxic, and immediately habitable healthy wall material.

[0026] Example 1. Addition of quartz sand and particle size screening:

[0027] Previous research in this invention has found that porous quartz sand can form a silicon-calcium bond with quicklime (electron microscopy shows that quicklime powder can enter the pores of quartz sand), which can give the prepared wall material better overall performance and water resistance.

[0028] This invention creatively explores a preparation method for quartz sand to possess a nanoscale porous structure and to form a silicon-calcium bond with slaked lime: Limestone and water are mixed and reacted at a mass ratio of 5:2, and pulverized quartz sand is added and stirred (high temperature gives the quartz sand a nanoscale porous structure, and stirring promotes silicon-calcium bonding), resulting in slaked lime containing quartz sand. Electron microscopy observation shows that the slaked lime powder can enter the pores of the quartz sand to form a silicon-calcium bond. The quartz sand prepared by this method, observed under an electron microscope, has a pore diameter of approximately 60-100 nm. Wall materials prepared according to the method described in Example 3 below were tested according to JG / T298-2010 water-resistant materials. The wall materials prepared by this invention (see Example 3)... Figure 1No cracking, powdering, strength reduction, or functional failure (such as loss of adhesion) occurred during tests such as soaking, high humidity environment, and freeze-thaw cycle, indicating that the product of this invention has broken through the bottleneck of traditional plaster application in humid environments.

[0029] Example 2. Screening of processing methods and grinding technology for glutinous rice

[0030] Traditional lime-glutinous rice mortar primarily uses high-temperature boiling to prepare glutinous rice, with a glutinous rice content as high as 20% or even higher. This results in significant starch loss and high costs due to the large amount of glutinous rice used. This invention, referring to JG / T298-2010 "Putty for External Wall Insulation," uses bonding strength as the evaluation index to screen processing methods and crushing processes for glutinous rice. High-speed shear mixing is used to prepare lime-glutinous rice mortar materials, and their bonding strength is examined. The results are shown in Table 1 below.

[0031] Table 1. Bond strength of lime-glutinous rice ash materials prepared by different glutinous rice processing methods and grinding processes

[0032]

[0033] Note: The quicklime (containing quartz sand) used in this Example 2 was prepared using the method described in Example 1.

[0034] Comparative studies have revealed that the present invention uses glutinous rice soaked in water for 3-6 hours, steamed over high heat for 20-30 minutes, and then pulverized at low temperature (0℃) at high speed to 100-150 mesh. The mass ratio of glutinous rice in the prepared lime-glutinous rice mortar is only 3%-5%, which can meet the bonding strength requirements of JG / T 298-2010 "Putty for External Wall Insulation" (should be >0.5MPa). Preferably, the rice is soaked in water for 5 hours, drained, steamed over high heat for 20 minutes until cooked, naturally dried, and then pulverized at low temperature (0℃) at high speed (the actual particle size is 120 mesh, i.e., about 125um). More preferably, the rice is soaked in water for 5 hours, drained, steamed over high heat for 20 minutes until cooked, naturally dried, frozen (-20℃) for storage, and then pulverized at low temperature (0℃) at high speed (the actual particle size is 150 mesh, i.e., about 90um). Conversely, if the glutinous rice is cooked at high temperature and then immediately pulverized at low temperature (0℃) at high speed (actual particle size of 100 mesh), and the amount of glutinous rice flour used reaches 15%, the resulting lime-glutinous rice mortar will meet the bonding strength requirements of JG / T 298-2010 "Putty for External Wall Insulation" (should be >0.5MPa).

[0035] Example 3. Improved preparation method of the present invention:

[0036] 1. Based on the exploratory research, the following prescription formulation is proposed:

[0037] The composition, by weight ratio (W / W), is 91.5% quicklime containing 10% quartz sand, 5% glutinous rice flour, 3% white sugar, 0.5% cotton, and an appropriate amount of volcanic ash.

[0038] 2. Preparation method:

[0039] 2.1. Preprocessing:

[0040] (1) Mix quicklime and water at a mass ratio of 5:2, disperse about 10% of the weight of quicklime in quartz sand (crushed to 60-100 mesh), cool, stir appropriately, and dry (so that the moisture content is less than 3%) to obtain hydrated lime containing 10% quartz sand.

[0041] (2) Soak glutinous rice in water for 3-6 hours, steam over high heat for 20-30 minutes, and grind at low temperature (0℃) and high speed to 100-150 mesh glutinous rice powder;

[0042] (3) Grind white sugar at low temperature (0℃) and high speed to 120-150 mesh;

[0043] (4) Grind the cotton into 100-150 mesh.

[0044] 2.2. Mixing:

[0045] Weigh out the prescribed amounts of the pretreated quicklime containing quartz sand, glutinous rice flour, cotton flour, and white sugar, and add them sequentially to a mixing container. Mix thoroughly using a high-speed shearing method (stirring paddle speed 100 rpm, cutter speed 800 rpm, mixing for 5-8 minutes).

[0046] 2.3. Color Correction:

[0047] Add an appropriate proportion of volcanic ash to the wall material of the desired color (stirring paddle speed 100 rpm, cutter speed 800 rpm, mix for 3 minutes).

[0048] 3. Performance Testing:

[0049] Its performance will be evaluated according to the following seven criteria:

[0050] (1) Formaldehyde, benzene, toluene, ethylbenzene, and xylene were tested according to GB18582-2020, the national standard of the People's Republic of China, "Limits of Hazardous Substances in Interior Wall Coatings for Interior Decoration and Renovation Materials," as well as heavy metals such as mercury, lead, cadmium, and chromium. Results showed that no formaldehyde, benzene, toluene, ethylbenzene, or xylene, nor heavy metals such as mercury, lead, cadmium, and chromium were detected in this product. See [link to product details]. Figures 2-1 to 2-5 .

[0051] (2) Water-resistant material testing was conducted according to JG / T 298-2010: The material should not exhibit cracking, powdering, strength reduction, or functional failure (such as loss of adhesion) during immersion, high humidity, and freeze-thaw cycles. Results showed that this product did not exhibit cracking, powdering, strength reduction, or functional failure (such as loss of adhesion) during immersion, high humidity, and freeze-thaw cycles, indicating that this product overcomes the bottleneck of traditional plaster applications in humid environments. See [link to relevant documentation]. Figure 1 .

[0052] (3) Fire resistance testing of building materials was conducted according to GB8624-2012 for Class A1 rating: Class A1 is the highest fire resistance rating in the EU standard EN 13501-1, and the Chinese domestic standard for Class A1 is even more stringent. The results show that the fire resistance rating of this product exceeds the national standard for Class A1 by 6 times. See... Figure 3 .

[0053] (4) Antimicrobial performance was tested according to GB / T21866-2008 (Level 1): Level 1 antimicrobial performance is suitable for places with high antimicrobial performance requirements. Results are as follows... Figure 4 As shown: This product has an antibacterial rate of 99.99% against Escherichia coli and Staphylococcus aureus, with antibacterial performance of Grade 1, making it suitable for places with high antibacterial performance requirements.

[0054] (5) According to GB / T1741-2020, the mildew resistance performance was tested at level 0: Level 0 mildew resistance means that none of the eight major mildews, including Aspergillus niger, Aspergillus flavus, and Trichoderma viride, should grow. Results are as follows... Figure 5 As shown: This product has a mold prevention level of 0, meaning that it does not grow in any of the eight major molds, including Aspergillus niger, Aspergillus flavus, and Trichoderma viride.

[0055] (6) Radionuclide limits shall be tested according to GB 6566-2010 (Class A): The requirements for Class A materials must be met. For Class A building materials, their production, sales, and use are not restricted. Results are as follows: Figure 6 As shown: This product belongs to Class A building materials.

[0056] (7) Interior wall coatings for children's rooms shall be tested according to GB / T34676-2017: They shall meet all requirements for interior wall coatings for children's rooms. Results are as follows: Figure 7-1 and Figure 7-2 As shown: This product meets all the requirements for interior wall paint for children's rooms and can be used by pregnant women, children, the elderly, and other people with respiratory sensitivities.

[0057] Example 4. Addition of sugar and screening of sugar

[0058] Traditional lime-glutinous rice mortar can also corrode and mold in humid environments. Previous studies have found that adding sugar to the traditional lime-glutinous rice mortar process can improve the corrosion and mold growth in humid environments.

[0059] Referring to the improved preparation method described in Example 3, lime-glutinous rice ash materials were prepared with or without sugar, and with 3% white sugar or 3% brown sugar respectively. The antibacterial performance was tested according to the GB / T21866-2008 standard at level 1. The antibacterial rate % = average number of recovered bacteria (cfu / tablet) of the test sample after 24 hours / average number of recovered bacteria (cfu / tablet) of the blank control sample after 24 hours * 100%. The antibacterial rate results of each test sample are shown in Table 2 below.

[0060] Table 2. Results of antibacterial performance test:

[0061]

[0062] Note: The lime-glutinous rice ash material prepared in Example 4 contains cotton fibers.

[0063] The results showed that the lime-glutinous rice ash sample with added white sugar achieved an antibacterial effect of 99.99%, classifying it as antibacterial performance level I. The lime-glutinous rice ash sample with added brown sugar achieved an antibacterial performance level II, while the lime-glutinous rice ash sample without added sugar exhibited poor antibacterial performance. Therefore, white sugar is preferred in this invention.

[0064] Example 5. Addition of cotton to screening

[0065] Traditional lime-glutinous rice mortar can also crack in dry environments. Conventional wall materials such as putty powder often reduce cracking caused by drying shrinkage by adding wood fiber materials to form a network structure in the putty powder, thereby dispersing stress. However, the use of wood fiber will cause the problem of reduced bonding strength, so it is necessary to continue to improve it.

[0066] Previous research in this invention found that adding cotton to the traditional lime-glutinous rice mortar process effectively prevents cracking. This embodiment compares the crack resistance of conventional wood fiber (poplar fiber), hemp fiber, and cotton fiber using the preparation method described in Example 3. Initial drying crack resistance (3h) was tested according to the JB / T298-2010 water-resistant material testing standard, and the results are shown in Table 3 below.

[0067] Table 3. JB / T298-2010 Initial Drying Crack Resistance Test (3h)

[0068]

[0069] The results showed that adding cotton had a better effect in preventing cracking and did not reduce the bonding strength.

[0070] II. Research on the Proportioning and Effect Testing of the Wall Material Formula of the Invention

[0071] The wall materials were prepared according to the preparation method described in Example 3, based on the formulation composition and proportions in Table 4, and their performance was examined according to the seven standards described in Example 3.

[0072] Table 4. Prescription ratios and test results are as follows:

[0073]

[0074]

[0075] Analysis of the test indicators of the wall materials prepared in Examples 3 and 6-15 above shows that, based on the mass ratio (W / W), the wall materials prepared with quicklime (10% quartz sand): glutinous rice flour: white sugar: cotton = (88.7-93.5):(3-10):(2-5):(0.3-0.8) basically meet all the standard requirements; that is, based on the mass ratio (W / W), the wall materials prepared with 88.7%-93.5% quicklime containing 10% quartz sand, 3%-10% glutinous rice flour, 2%-5% white sugar, and 0.3%-0.8% cotton, with an appropriate amount of volcanic ash for color adjustment, meet all the standard requirements described in Example 3.

[0076] Summary of the technical effects and advantages of the wall material of this invention (see) Figure 8 ):

[0077] 1. Completely free of formaldehyde, benzene, and other toxic chemicals, ensuring a high level of health benefits. Ready to move in immediately after installation, no waiting required.

[0078] 2. It is highly water-resistant, washable, and suitable for use in humid environments.

[0079] 3. It has high hardness, is scratch and wear resistant, and its Mohs hardness can reach 5-5.5 after drying, making it as hard as stone and durable.

[0080] 4. It can solve the problems of blistering, powdering, and peeling that occur after wall materials have been soaked in alkali due to efflorescence caused by the cement itself. This is something that putty powder, latex paint, and artistic paint cannot do.

[0081] 5. Quicklime itself has natural antibacterial and bactericidal properties, preventing mold and mildew, and is less prone to mold spots and mildew problems caused by moisture in traditional wall materials.

[0082] 6. It has high fire resistance and has passed the A1 fire rating certification.

[0083] 7. It has strong weather resistance and durability, and is highly adaptable to low temperature, high temperature and high salinity environments.

[0084] 8. It can be used not only indoors, but also directly outdoors.

[0085] 9. No need for putty, primer, topcoat, or latex paint; only one material is needed to complete the finished wall surface construction.

[0086] 10. It has a rich texture, strong plasticity, and a more natural texture compared to artistic paint.

[0087] The above embodiments are preferred embodiments of the present invention, but the embodiments of the present invention are not limited to the above embodiments. Any changes, modifications, substitutions, combinations, or simplifications made without departing from the spirit and principle of the present invention shall be considered equivalent substitutions and shall be included within the protection scope of the present invention.

Claims

1. A non-toxic, environmentally friendly, novel wall covering material, characterized in that: The ratio of quicklime containing 10% quartz sand to glutinous rice flour to sugar to natural fiber is (88.7-93.5): (3-10): (2-5): (0.3-0.8) by mass ratio (W / W). The mixture is then sheared and thoroughly mixed. The sugar is one or both of white sugar and brown sugar; The natural fiber is cotton; The method for preparing the glutinous rice flour is as follows: soak glutinous rice in water for 3-6 hours, steam over high heat for 20-30 minutes, and then grind it at low temperature and high speed to 100-150 mesh glutinous rice flour, wherein the low temperature is 0℃; The method for preparing hydrated lime containing 10% quartz sand is as follows: quicklime and water are mixed and reacted at a mass ratio of 5:2, and quartz sand of 10% of the weight of quicklime is dispersed and added. After cooling, the mixture is stirred appropriately and dried so that the moisture content is less than 3%, thereby obtaining hydrated lime containing 10% quartz sand; the quartz sand is crushed to 60-100 mesh.

2. The wall material according to claim 1, characterized in that: The sugar is pulverized at low temperature and high speed to 120-150 mesh; the natural fiber is pulverized to 100-150 mesh, and the low temperature is 0℃.

3. The wall covering of claim 2, wherein: The sugar is white granulated sugar.

4. The wall covering of claim 1, wherein: Based on a mass ratio (W / W), the ratio of quicklime containing 10% quartz sand to glutinous rice flour to sugar to natural fiber is 91.5:5:3:0.

5.

5. The wall covering of claim 1, wherein: Different colors of wall materials can be created by adding appropriate proportions of volcanic ash.

6. A method for preparing a non-toxic, environmentally friendly, novel wall material, characterized by: The wall material according to any one of claims 1-4 is weighed and prepared. The prescribed amounts of quicklime containing 10% quartz sand, glutinous rice flour, cotton, and sugar are added sequentially to a mixing container and mixed thoroughly using a high-speed shearing method to obtain the final product. The high-speed shearing method is a mixing paddle speed of 100 rpm and a cutter speed of 800 rpm, and mixing for 5-8 minutes.

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