Environment-friendly formula and application of novel fireproof antibacterial decorative plate

Abstract

The invention discloses an environment-friendly formula and application of a novel fireproof antibacterial decorative sheet, and relates to the technical field of fireproof antibacterial decorative sheets, the novel fireproof antibacterial decorative sheet comprises a base body layer, a flame-retardant antibacterial layer, a surface protection layer and a mineral admixture, the flame-retardant antibacterial layer is coated on the outer surface of the base body layer, the base body layer is composed of a glass magnesium flat plate, and the mineral admixture is coated on the surface protection layer. The glass magnesium flat plate comprises magnesium oxide, magnesium chloride and modified volcanic ash, the mineral admixture is prepared by adding 5-15 wt% of metakaolin and 5-15 wt% of silica fume which are compounded in a mass ratio of 3: 1 into the matrix layer. By means of the glass magnesium flat plate, high strength and environmental protection performance of the base body are achieved, the problems that the decorative plate base body is insufficient in strength and poor in environmental protection performance are solved, the structural stability of the decorative plate base body is improved, and resource recycling is achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of fireproof and antibacterial decorative plates, in particular to an environment-friendly formula of a novel fireproof and antibacterial decorative plate and application. BACKGROUND

[0002] As a core material for building decoration, furniture manufacturing and interior decoration, the performance of the decorative plate directly affects the building safety and user health. With the rapid development of the building industry and the improvement of people's requirements for living environment, the fireproof and antibacterial decorative plate can not only effectively delay the spread of fire and reduce the risk of fire, but also inhibit the breeding of bacteria and mold and reduce the spread of diseases caused by microbial pollution. However, the traditional products generally use adhesive containing formaldehyde, which leads to long-term over-standard of indoor formaldehyde after decoration; halogen flame retardants have good flame retardant effect, but release toxic gases such as dioxin during combustion; silver-based antibacterial agents have the problem of ecological toxicity caused by ion loss. In addition, the synergistic effect between single functional additives is insufficient, which easily causes mutual weakening of the flame retardant and antibacterial properties.

[0003] Patent CN106364071B discloses an antibacterial, mildew-resistant, corrosion-resistant and fireproof high-pressure decorative plate and a production method thereof. The above-mentioned patent realizes that the buffer layer is made of kraft paper impregnated with thermosetting alcohol-soluble phenolic resin; the decorative layer is made of decorative paper coated with an epoxy resin of a dual-curing system of thermal curing and photocuring added with an antibacterial agent, and the decorative plate is water-resistant, moisture-resistant, impact-resistant, has good dimensional stability, is surface corrosion-resistant, pollution-resistant, wear-resistant, antibacterial and mildew-resistant, easy to clean, does not use aldehyde-containing resin on the surface, and has low formaldehyde emission.

[0004] The above-mentioned patent has remarkable effect on the performance improvement of the decorative plate. Through specific material combination, the decorative plate realizes the characteristics of water resistance, moisture resistance, impact resistance, good dimensional stability, surface corrosion resistance, pollution resistance, wear resistance, antibacterial and mildew resistance, and is easy to clean, does not use aldehyde-containing resin, and has low formaldehyde emission. However, the research on fireproof and antibacterial properties is not involved.

[0005] Therefore, the present application proposes an environment-friendly formula of a novel fireproof and antibacterial decorative plate and application, which can realize the addition of 3:1 compounded metakaolin and silica ash mineral admixture to the glass-magnesium flat plate substrate layer, and form a protective layer by layered spraying to improve the performance of the substrate. SUMMARY

[0006] The present application aims to provide an environment-friendly formula of a novel fireproof and antibacterial decorative plate and application to solve the technical problems of long-term over-standard of indoor formaldehyde after conventional decoration and performance reduction caused by imperfect coordination between raw materials.

[0007] To achieve the above object, the present application provides the following technical scheme: including base layer, fire-retardant antibacterial layer, surface protection layer and mineral admixture, the fire-retardant antibacterial layer is coated on the outer surface of the base layer, the base layer is composed of magnesium oxide, magnesium chloride and modified volcanic ash, the mineral admixture is 3:1 compounded metakaolin and silica ash in base layer, and the metakaolin is 5-15wt%.

[0008] Preferably, the fire-retardant antibacterial layer comprises alginate-based flame retardant, polyhexamethylene phosphonate and carbon nanotube, the polyhexamethylene phosphonate is formed into a film by loading acrylic emulsion, the polyhexamethylene phosphonate is 15-25% in the solid content of the fire-retardant antibacterial layer, the mass ratio of alginate to polyhexamethylene phosphonate is 1:0.8-1.2, and the carbon nanotube accounts for 10-20% of the total mass of the fire-retardant antibacterial layer.

[0009] Preferably, the surface protection layer is compounded by TD-808 protective agent and Bp-9200 protective agent at a mass ratio of 1:1-2, and the thickness is 20-50μm. The TD-808 protective agent is water-based fluorocarbon resin, the Bp-9200 protective agent is organic silicon modified acrylate, the surface protection layer is applied by spraying process twice, the first spraying thickness is 10-20μm, and the second spraying thickness is 10-30μm.

[0010] Preferably, the fire-retardant antibacterial layer and the surface protection layer are mixed with silane coupling agent KH-570 and quartz sand with a particle size of 20-40 mesh, the total volume of the quartz sand is 40-60%, the quartz sand is pretreated by hydrochloric acid, the surface roughness Ra is 1.5-2.5μm, the pretreatment mode is that the quartz sand is immersed in 2-5wt% KH-570 ethanol solution for 30min and dried at 80℃.

[0011] Preferably, the alginate is potassium alginate, the viscosity of the potassium alginate is 300-800mPa·s, the diameter of the carbon nanotube is 10-20nm, the length is 10-30nm, and a continuous network structure is formed in the fire-retardant antibacterial layer, the coating thickness of the fire-retardant region in the fire-retardant antibacterial layer is 100-200μm, and the coating thickness of the antibacterial region is 30-80μm. The alginate, sodium dihydrogen phosphate and sodium phosphate are configured into a solution, the silver nitrate solution is dropped into the solution, stirring is carried out at pH=9-10 and 45℃ until a golden yellow gel body is formed, the molar ratio of silver nitrate to phosphate is 1:1, the gel body is vacuum degassed and then placed for 10-20min to form the alginate polysaccharide gel solution. Potassium alginate is modified with beeswax by mixing potassium alginate and water at a mass ratio of 1:40-60, dispersing at 70℃, adding 3-5% beeswax (by weight of potassium alginate), homogenizing at 10000r / min for 3-5min, quick-freezing with liquid nitrogen, and then freeze-drying at -40℃ for 8-10h to form a porous modified carrier.

[0012] Preferably, the matrix layer comprises, by mass parts, 300-400 parts of modified magnesium oxysulfate cement, 300-400 parts of quartz sand, 50-100 parts of mineral admixture, 3-5 parts of polypropylene fiber, 20-30 parts of inorganic flame retardant, and 2-3 parts of water-reducing agent. Take 150-200 parts of quartz sand with a particle size of 20-40 mesh, and take 150-200 parts of quartz sand with a particle size of 40-80 mesh. The inorganic flame retardant is a mixture of aluminum hydroxide and zinc borate in a mass ratio of 5:1. The flame-retardant and antibacterial layer consists of the following components by mass percentage: 50–80 wt% potassium alginate, 5–15 wt% silver phosphate, 8–20 wt% polyhexamethylene guanidine phosphate, and 2–8 wt% carbon nanotubes. Modified magnesium oxysulfate cement is made by blending industrial by-product gypsum and lightly calcined magnesium oxide in a molar ratio of 1:3, and adding sodium citrate at a mass of 0.5-1% of the cement.

[0013] Preferably, the acrylic emulsion has a glass transition temperature of -10 to 5°C, the polyhexamethylene sarcosinate has a degree of polymerization of >60, the metakaolin content is 5 to 8% of the total mass of the cementitious material, and the water-cement ratio of the matrix layer is 0.22 to 0.25. The flame-retardant and antibacterial layer is coated with a calcium borate nanolayer accounting for 0.5-2% of the fiber surface mass. The nascent fibers are sprayed with a 0.1-0.3 wt% boron salt solution 1-3 times. After spraying, the fibers are steam-dried at 95-103℃ for 3-10 minutes. The ratio of boric acid to borax is 4:1. CO2 gas is introduced during the boron salt solution spraying at a flow rate of 0.5-1 L / min. The humidity is controlled at 70-80% during the steam drying stage.

[0014] Preferably, the polyhexamethylene guanidine phosphate and carbon nanotubes construct a composite network. A 0.1 wt% polyhexamethylene guanidine phosphate solution and a suspension of potassium alginate and carbon nanotubes are alternately coated onto the substrate layer. Each layer is dried at 60°C after coating, and the coating is repeated 5 to 20 times to form a conductive network on the fiber surface. During the alternating coating process, 0.05 to 0.1 wt% polyvinylpyrrolidone K30 is added to the polyhexamethylene guanidine phosphate solution. After each double layer coating, the device is treated with a pulsed electric field for 2 minutes. The distance between the positive and negative electrodes is 10 cm. The electrode plate surface is coated with a polytetrafluoroethylene insulating layer. After the electric field treatment, a graphene oxide coating layer with a thickness of 5 to 10 nm is sputtered onto the surface of the carbon nanotube network. The suspension of potassium alginate and carbon nanotubes was prepared as follows: the potassium alginate solution concentration was 0.1 wt%, the amount of carbon nanotubes added was 1-5% of the mass of sodium alginate, and the suspension was dispersed by ultrasonication at 300W for 30 min and then allowed to stand for 48 h to obtain the stable suspension phase. Before compounding metakaolin and silica fume, mechanical activation treatment is performed. The mixture is then ground in a ball mill with zirconia balls as the medium at a ball-to-material ratio of 5:1 and a rotation speed of 300 r / min for 1 hour. The metakaolin is incorporated as follows: metakaolin with a particle size ≤10μm and a specific surface area ≥20m² / g is premixed with polypropylene and glass fiber in a high-speed mixer at 100-120℃ for 10 minutes to fill pores and consume free Ca(OH)2. When the compound is blended with polypropylene fiber, 0.1-0.5% of an aminated ionic liquid and 0.5% of nano-calcium carbonate nucleating agent by weight of the compound are added.

[0015] Preferably, the decorative panel is used for hospital operating room walls, laboratory fume hoods, fireproof partitions in high-rise buildings, and ceilings in public transportation waiting halls.

[0016] Preferably, the decorative panel is also suitable for walls of biosafety laboratories at level P2 or above and for partitions of cleanrooms with constant temperature and humidity.

[0017] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention achieves high strength and environmental performance of the substrate layer through a glass magnesium plate, solving the problems of insufficient strength and poor environmental performance of the decorative board substrate, and improving the structural stability and resource recycling of the decorative board substrate; 2. This invention achieves efficient fire resistance and long-lasting antibacterial function through a flame-retardant and antibacterial layer, solving the problems of insufficient flame retardant performance and short-lived antibacterial effect of decorative panels, improving the degree of automation, enhancing the user experience, and significantly improving the fire resistance rating of decorative panels and their continuous inhibition of bacteria. 3. This invention achieves strong interlayer bonding and surface weather protection by mixing silane coupling agent with hydrochloric acid-pretreated quartz sand, solving the problems of easy peeling between decorative panel layers and easy surface erosion by external environment, enhancing interlayer adhesion and improving surface stain resistance and aging resistance. 4. This invention achieves efficient loading and long-lasting release of flame-retardant and antibacterial components by modifying potassium alginate with beeswax, solving the problems of easy loss and rapid efficacy decay of flame retardants and antibacterial agents in decorative panels, extending the fireproof and antibacterial validity period of decorative panels and improving their durability. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the process flow of the present invention; Figure 2 This is a schematic diagram of the flame-retardant and antibacterial layer structure of the present invention; Figure 3This is a schematic diagram of the substrate layer preparation process of the present invention; Figure 4 This is a schematic diagram illustrating an embodiment of the surface protective layer of the present invention. Detailed Implementation

[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Please see Figure 1 , Figure 2 and Figure 3 This invention provides an embodiment of an environmentally friendly formula for a novel fire-resistant and antibacterial decorative panel, comprising a substrate layer, a flame-retardant and antibacterial layer, a surface protective layer, and mineral admixtures. The flame-retardant and antibacterial layer is coated on the outer surface of the substrate layer. The substrate layer is composed of a glass-magnesium oxide plate containing magnesium oxide, magnesium chloride, and modified volcanic ash. The mineral admixtures are a mixture of metakaolin and silica fume in a 3:1 mass ratio added to the substrate layer, with the metakaolin comprising 5-15 wt%. Between the flame-retardant and antibacterial layer and the surface protective layer, there is a mixture of silane coupling agent KH-570 and quartz sand with a particle size of 20-40 mesh, accounting for 40-60% of the total volume of quartz sand. The quartz sand is pretreated with hydrochloric acid, and the surface roughness Ra is 1.5-2.5 μm. The pretreatment method is to immerse the quartz sand in a 2-5 wt% KH-570 ethanol solution for 30 min and then dry it at 80℃. Further, two pretreatment processes were performed: first, the admixture was ball-milled and activated using zirconia balls as the medium at a ball-to-material ratio of 5:1, continuously ball-milled at 300 rpm for 1 hour; second, premixed fibers were prepared by mixing polypropylene fibers with 0.3 wt% aminated ionic liquid and 0.5 wt% nano-calcium carbonate, and treated at 120°C for 10 minutes; then, the cementitious material was dry-mixed for 2 minutes, followed by the addition of a magnesium chloride solution with a water-to-cement ratio of 0.24 and stirring for 5 minutes, and finally the premixed fibers were added and stirring continued for 3 minutes. After stirring, the mixture was pressed and molded, subjected to a pressure of 15 MPa, and held for 30 minutes to form the matrix layer. The matrix layer is composed of: 350 parts by weight of modified magnesium oxysulfate cement, 180 parts by weight of 20-40 mesh quartz sand, 170 parts by weight of 40-80 mesh quartz sand, 70 parts by weight of mineral admixtures, 4 parts by weight of polypropylene fiber, 25 parts by weight of aluminum hydroxide / zinc borate, and 2.5 parts by weight of polycarboxylate superplasticizer. The main raw materials of the modified magnesium oxysulfate cement are magnesium oxide with an active content of 85% and magnesium chloride with a MgCl2·6H2O content of ≥99%, and it also contains modified pozzolanic material with a D50 of 12μm and a SiO2 content of 78%.

[0021] Then, a potassium alginate solution of 300 mPa·s was prepared, and 3 wt% beeswax was added to it. The mixture was homogenized at 10000 r / min for 4 minutes, then rapidly frozen in liquid nitrogen and freeze-dried at -40℃. Next, a coating was applied by alternately spraying 0.1 wt% PHMG phosphate and alginate / carbon nanotube suspension. Each layer was dried at 60℃ after spraying, and the double coating was repeated 10 times to obtain a flame-retardant and antibacterial layer. Finally, TD-808 fluorocarbon resin and BP-9200 organosilicon acrylate were compounded in a ratio of 1:1.5. The first spray coating was 15 μm thick and the pressure was 0.2 MPa. The second spray coating was 25 μm thick and the pressure was 0.3 MPa. The two coatings were cured at an interval of 30 minutes to obtain a surface protective layer.

[0022] Please see Figure 1 , Figure 3 and Figure 4 The present invention provides an embodiment of an environmentally friendly formula for a novel fire-retardant and antibacterial decorative panel, wherein the flame-retardant and antibacterial layer comprises an alginate-based flame retardant, polyhexamethylene sarcosinate, and carbon nanotubes. The polyhexamethylene sarcosinate is loaded with an acrylic emulsion to form a thin film. The solid content of polyhexamethylene sarcosinate in the flame-retardant and antibacterial layer is 15-25%, the mass ratio of alginate to polyhexamethylene sarcosinate is 1:0.8-1.2, and the carbon nanotubes account for 10-20% of the total mass of the flame-retardant and antibacterial layer. The alginate is potassium alginate, with a viscosity of 300–800 mPa·s. The carbon nanotubes have a diameter of 10–20 nm and a length of 10–30 nm, forming a continuous network structure in the flame-retardant and antibacterial layer. The flame-retardant region of the flame-retardant and antibacterial layer has a coating thickness of 100–200 μm, and the antibacterial region has a coating thickness of 30–80 μm. Alginate, sodium dihydrogen phosphate, and sodium phosphate were prepared into a solution. Silver nitrate solution was added dropwise and stirred at pH 9-10 and 45°C until a golden yellow gel was formed. The molar ratio of silver nitrate to phosphate was 1:1. After vacuum degassing, the gel was allowed to stand for 10-20 minutes to form an algae polysaccharide gel solution. Potassium alginate is modified with beeswax by mixing potassium alginate and water at a mass ratio of 1:40-60, dispersing at 70℃, adding 3-5% beeswax by mass of potassium alginate, homogenizing at 10000r / min for 3-5min, quick-freezing with liquid nitrogen, and freeze-drying at -40℃ for 8-10h to form a porous modified carrier. Further, 320 parts of modified magnesium oxysulfate cement, 160 parts of 20-40 mesh quartz sand, 190 parts of 40-80 mesh quartz sand, 60 parts of mineral admixtures, 3.5 parts of polypropylene fiber, 22 parts of inorganic flame retardant, and 2.2 parts of water-reducing agent are mixed. The modified magnesium oxysulfate cement, quartz sand, mineral admixtures, polypropylene fiber, inorganic flame retardant and water-reducing agent compounded with aluminum hydroxide and zinc borate in a 5:1 ratio are mixed. The modified magnesium oxysulfate cement is made by compounding industrial by-product gypsum and lightly calcined magnesium oxide in a 1:3 molar ratio, adding 0.8% sodium citrate, adding water at a water-cement ratio of 0.22 and stirring, pouring into a mold to form, and curing to obtain the matrix layer; Take 55wt% potassium alginate, 8wt% silver phosphate, 18wt% polyhexamethylene guanidine phosphate, and 7wt% carbon nanotubes with a diameter of 12nm and a length of 15nm. Mix potassium alginate with water at a ratio of 1:50, disperse at 70℃, add 4% beeswax, homogenize and freeze-dry to form a porous carrier. Prepare a potassium alginate and carbon nanotube suspension, disperse ultrasonically and let stand. Alternately coat the substrate layer with 0.1wt% polyhexamethylene guanidine phosphate solution, dry each layer at 60℃, repeat 8 double layers, and treat each double layer with a pulsed electric field during the process. Finally, sputter a graphene oxide coating layer, with a 120μm coating in the flame-retardant area and a 40μm coating in the antibacterial area. Quartz sand (20-40 mesh) is pretreated with hydrochloric acid to Ra=Ra=1.8μm, impregnated with 3wt% KH-570 ethanol solution for 30min, dried at 80℃, and mixed with silane coupling agent KH-570, with quartz sand accounting for 45% of the volume. It is then coated onto a flame-retardant and antibacterial layer. TD-808 and Bp-9200 are compounded in a 1:1 ratio. The first spray is 12μm thick, the second is 18μm thick, and the total thickness is 30μm. Laboratory fume hoods frequently come into contact with chemical reagents. The protective layer on the surface of this material is resistant to chemical corrosion and can withstand the erosion of various reagents. It also boasts excellent fire resistance, capable of handling open flames or high temperatures that may occur during experiments, ensuring experimental safety.

[0023] According to GB / T8624-2012, a 200×200×10mm sample was cut and placed in an environment of (23±2)℃ / (50±5)%RH for 48h. The heat release rate was tested using a cone calorimeter, and the total heat release and combustion growth rate index were recorded. The flue gas generation rate was tested simultaneously. The results showed that THR600s≤2.0MJ / m² and FIGRA0.2MJ≤120W / s, which met the A1 grade. Please see Figure 1 , Figure 2 and Figure 3The present invention provides an embodiment of an environmentally friendly formula for a novel fireproof and antibacterial decorative panel, wherein the surface protective layer is composed of TD-808 protective agent and Bp-9200 protective agent in a mass ratio of 1:1 to 2, and the thickness is 20 to 50 μm. TD-808 protective agent is a water-based fluorocarbon resin, and Bp-9200 protective agent is an organosilicon-modified acrylate. The surface protective layer is applied in two stages by spraying. The thickness of the first spray is 10-20 μm, and the thickness of the second spray is 10-30 μm. The acrylic emulsion has a glass transition temperature of -10 to 5°C, the degree of polymerization of polyhexamethylene sarcosinate is >60, the metakaolin content is 5 to 8% of the total mass of the cementitious material, and the water-cement ratio of the matrix layer is 0.22 to 0.25. The flame-retardant and antibacterial layer is coated with a calcium borate nanolayer accounting for 0.5-2% of the fiber surface mass. The nascent fibers are sprayed with a 0.1-0.3 wt% boron salt solution 1-3 times. After spraying, the fibers are steam-dried at 95-103℃ for 3-10 minutes. The ratio of boric acid to borax is 4:1. CO2 gas is introduced during the boron salt solution spraying at a flow rate of 0.5-1 L / min. The humidity is controlled at 70-80% during the steam drying stage. Further, 380 parts of modified magnesium oxysulfate cement, 200 parts of 20-40 mesh quartz sand, 200 parts of 40-80 mesh quartz sand, 90 parts of mineral admixture (8% metakaolin), 5 parts of polypropylene fiber, 28 parts of inorganic flame retardant, and 3 parts of water-reducing agent were mixed. A water-cement ratio of 0.24 was used to prepare the matrix layer; 70 wt% potassium alginate, 12 wt% silver phosphate, 12 wt% polyhexamethylene guanidine phosphate, and 6 wt% carbon nanotubes (18 nm in diameter and 25 nm in length) were used. Fifteen alternating double layers were applied: 180 μm for the flame-retardant area and 60 μm for the antibacterial area. The quartz sand Ra=2.2 μm, accounting for 55% of the volume, was a 1:2 mixture of TD-808 and Bp-9200. The first layer was sprayed to a thickness of 20 μm, the second layer 30 μm, for a total thickness of 50 μm. Fire crystal board is a new type of composite board with modified volcanic ash as the core functional admixture. It belongs to the upgraded branch of glass magnesium plate. Its matrix layer is based on glass magnesium plate with magnesium oxide and magnesium chloride system. The volcanic ash is activated by the 3:1 compound of metakaolin and silica fume (8wt% metakaolin) to activate the cementing activity of volcanic ash. The active SiO2 and Al2O3 in volcanic ash react with Mg(OH)2 in the system to generate hydrated magnesium silicate gel, forming a three-dimensional network structure. This not only enhances the antibacterial properties, but also improves the density through the filling effect. Based on the porous structure of volcanic ash, bacteria are adsorbed. Combined with silver phosphate nanoparticles, continuous antibacterial effect is achieved. Volcanic ash and modified magnesium oxysulfate cement synergistically hydrate, generating needle-like water The chemical products intertwine to form a rigid skeleton, achieving a compressive strength of 45MPa and a flexural strength of ≥12MPa after 28 days. Four parts of polypropylene fiber and 15nm diameter carbon nanotubes form a multi-level reinforcing network. The carbon nanotubes construct a continuous conductive network in the flame-retardant and antibacterial layer. Simultaneously, pulsed electric field treatment promotes the bonding between the fiber and the matrix interface, enhancing impact strength. An automated layered casting + microwave curing process is adopted, shortening the matrix layer molding cycle to 4 hours compared to existing conventional methods, with a daily production capacity of 5000㎡. Through online laser thickness measurement and antibacterial performance sampling inspection, the quality pass rate is consistently above 99.5%. In terms of cost, industrial by-product gypsum replaces 30% of lightly calcined magnesium oxide, reducing raw material costs by 15%.

[0024] According to GB / T21866-2008, inoculate with 0.2 mL of bacterial suspension (Escherichia coli ATCC25922, concentration 1×10⁻⁶). 5 The sample was coated with CFU / mL and covered with a polyethylene film to prevent evaporation. It was then incubated at (37±1)℃ / 90%RH for 24h. The bacterial cells were washed off with 10mL PBS buffer, serially diluted, and poured onto nutrient agar plates. The colonies were counted and the antibacterial rate was calculated. The antibacterial rate against Escherichia coli reached 99.95%, while the colony count in the untreated control group was >250 CFU / cm².

[0025] Please see Figure 1 , Figure 3 and Figure 4 One embodiment of the present invention is an environmentally friendly formula for a novel fireproof and antibacterial decorative panel, comprising 150-200 parts of quartz sand with a particle size of 20-40 mesh and 150-200 parts of quartz sand with a particle size of 40-80 mesh, and an inorganic flame retardant consisting of aluminum hydroxide and zinc borate compounded in a mass ratio of 5:1. The flame-retardant and antibacterial layer consists of the following components by mass percentage: 50–80 wt% potassium alginate, 5–15 wt% silver phosphate, 8–20 wt% polyhexamethylene guanidine phosphate, and 2–8 wt% carbon nanotubes. Modified magnesium oxysulfate cement is made by blending industrial by-product gypsum and lightly calcined magnesium oxide in a molar ratio of 1:3, and adding sodium citrate at a mass of 0.5-1% of the cement. The suspension of potassium alginate and carbon nanotubes is prepared as follows: the potassium alginate solution concentration is 0.1wt%, the amount of carbon nanotubes added is 1-5% of the mass of sodium alginate, and the mixture is ultrasonically dispersed at 300W for 30 minutes and then allowed to stand for 48 hours. The stable suspension phase is then collected. The decorative panels are used for hospital operating room walls, laboratory fume hoods, fireproof partitions in high-rise buildings, and ceilings in public transportation waiting halls; the decorative panels are also suitable for walls of biosafety laboratories at level P2 and above, and for partitions in constant temperature and humidity clean workshops. Further, 300 parts of modified magnesium oxysulfate cement, 150 parts of 20-40 mesh quartz sand, 150 parts of 40-80 mesh quartz sand, 50 parts of mineral admixture (6% metakaolin), 3 parts of polypropylene fiber, 20 parts of inorganic flame retardant, and 2 parts of water-reducing agent are mixed. A water-cement ratio of 0.22 is used to form the base layer. Five alternating double layers are applied: 50 wt% potassium alginate, 5 wt% silver phosphate, 20 wt% polyhexamethylene guanidine phosphate, and 2 wt% carbon nanotubes (10 nm in diameter and 10 nm in length). The flame-retardant area is coated with 100 μm, the antibacterial area with 30 μm, and the quartz sand Ra=1.5 μm, accounting for 40% of the volume. TD-808 and Bp-9200 are compounded in a 1:1 ratio. The first spray is 10 μm thick, the second spray is 10 μm thick, and the total thickness is 20 μm. The base layer, flame-retardant and antibacterial layer, and surface protective layer are applied using continuous rolling and simultaneous curing. Each layer is then rapidly cured by 80℃ infrared radiation, avoiding interlayer delamination issues associated with step-by-step production. Modified volcanic ash and metakaolin are compounded and their specific surface area is increased to 25 m² through mechanical activation ball milling for 1 hour. 2 / g, synergistically consumes free Ca(OH)2 with silica fume, reducing the porosity of the matrix layer to 8%. Carbon nanotubes simultaneously achieve the triple functions of conductivity, reinforcement, and flame retardancy, reducing the types of functional additives. Waterborne fluorocarbon resin TD-808 is compounded with organosilicon-modified acrylate Bp-9200, with VOC emissions ≤5g / L (national standard ≤100g / L), meeting green building standards. Through alternating coating, an "inorganic-organic" composite network is constructed. Polyhexamethylene guanidine phosphate and carbon nanotubes form a conductive pathway. Pulsed electric field treatment promotes molecular cross-linking, ultimately achieving integrated performance of fire resistance, antibacterial properties, and high strength.

[0026] Please see Figure 1 , Figure 2 and Figure 4 One embodiment of the present invention provides an environmentally friendly formula for a novel fireproof and antibacterial decorative panel, wherein the matrix layer comprises, by weight, 300-400 parts of modified magnesium oxysulfate cement, 300-400 parts of quartz sand, 50-100 parts of mineral admixtures, 3-5 parts of polypropylene fiber, 20-30 parts of inorganic flame retardant, and 2-3 parts of water-reducing agent. The polyhexamethylene guanidine phosphate and carbon nanotubes form a composite network. A 0.1 wt% polyhexamethylene guanidine phosphate solution and a suspension of potassium alginate and carbon nanotubes are alternately coated onto the substrate layer. Each layer is dried at 60°C after coating. The coating process is repeated 5 to 20 times to form a conductive network on the fiber surface. During the alternating coating process, 0.05 to 0.1 wt% polyvinylpyrrolidone K30 is added to the polyhexamethylene guanidine phosphate solution. After each double layer coating, the electrode is treated with a pulsed electric field for 2 minutes. The distance between the positive and negative electrodes is 10 cm. The electrode plate surface is coated with a polytetrafluoroethylene insulating layer. After the electric field treatment, a graphene oxide coating layer with a thickness of 5 to 10 nm is sputtered onto the surface of the carbon nanotube network. Before compounding metakaolin and silica fume, mechanical activation treatment is performed. The mixture is then ground in a ball mill with zirconia balls as the medium at a ball-to-material ratio of 5:1 and a rotation speed of 300 r / min for 1 hour. The metakaolin is incorporated as follows: metakaolin with a particle size ≤10μm and a specific surface area ≥20m² / g is premixed with polypropylene and glass fiber in a high-speed mixer at 100-120℃ for 10 minutes to fill pores and consume free Ca(OH)2. When the compound is blended with polypropylene fiber, 0.1-0.5% of an aminated ionic liquid and 0.5% of nano-calcium carbonate nucleating agent by weight of the compound are added. Further, 400 parts of modified magnesium oxysulfate cement, 200 parts of 20-40 mesh quartz sand, 200 parts of 40-80 mesh quartz sand, 100 parts of mineral admixture (8% metakaolin), 5 parts of polypropylene fiber, 30 parts of inorganic flame retardant, and 3 parts of water-reducing agent are mixed together. A water-cement ratio of 0.25 was used to prepare the substrate layer. Twenty alternating double layers were applied, consisting of 80wt% potassium alginate, 15wt% silver phosphate, 8wt% polyhexamethylene guanidine phosphate, and 8wt% carbon nanotubes (20nm in diameter and 30nm in length). The flame-retardant area was coated with 200μm of the substrate, and the antibacterial area with 80μm. The flame-retardant and antibacterial layers were also coated with a 1% calcium borate nanolayer. The substrate was then sprayed twice with a 0.2wt% borate solution (boric acid and borax in a 4:1 ratio), followed by CO2 (0.8L / min) and steam drying (100℃, 75% humidity) for 5min. Quartz sand with a Ra=2.5μm, comprising 60% of the volume, was mixed with TD-808 and Bp-9200 in a 1:2 ratio and sprayed twice, with a total thickness of 50μm. According to GB18580-2017, the sample was cut into 150×50mm specimens, the edges were sealed with aluminum foil, and placed in a 1m³ climate chamber at 23℃ / 45%RH with an air exchange rate of 1.0 times / h. After 72 hours, the gas inside the chamber was collected, and the formaldehyde concentration was determined by acetylacetone spectrophotometry. In this example, the release amount was ≤0.015mg / m³. 3 It reaches the E0 level limit of 0.025 mg / m³. 3 60%.

[0027] Working principle: First, the mineral admixture is ball-milled and activated using zirconia balls as the medium at a ball-to-material ratio of 5:1 for 1 hour to enhance its reactivity. Then, the mineral admixture is mixed with aminated ionic liquid and nano-calcium carbonate, and treated at 120℃ for 10 minutes to strengthen the bond between the fiber and the matrix. Next, the cementitious material is dry-mixed for 2 minutes, then a magnesium chloride solution with a water-to-cement ratio of 0.24 is added and stirred for 5 minutes. Finally, pre-mixed fibers are added and stirred for 3 minutes. After stirring, the mixture is pressed and molded to form a matrix layer composed of modified magnesium oxysulfate cement, quartz sand, and mineral admixtures. In the matrix layer, the modified magnesium oxysulfate cement and modified volcanic ash work synergistically to form a three-dimensional network structure through hydration, ensuring strength and providing an adhesion base. Simultaneously, the combination of mineral admixtures and volcanic ash also improves density and antibacterial properties.

[0028] Then, a potassium alginate solution was prepared, beeswax was added and homogenized for 4 minutes, followed by liquid nitrogen flash freezing and freeze-drying at -40℃. Simultaneously, carbon nanotubes and polyhexamethylene guanidine phosphate were treated to form a suspension. The phosphate and alginate / carbon nanotube suspension were alternately sprayed onto the surface of the formed substrate layer. Each layer was dried at 60℃, and the process was repeated multiple times to form a double-layer structure. The coating thickness of the flame-retardant and antibacterial areas was controlled according to requirements. The alginate-based flame retardant and polyhexamethylene guanidine phosphate worked synergistically, and the carbon nanotubes formed a continuous network. This enhanced the flame-retardant effect through the porous structure and achieved continuous antibacterial effect with the help of silver phosphate and polyhexamethylene guanidine phosphate. The pulsed electric field treatment also promoted the interfacial bonding of the components and improved the interlayer stability.

[0029] Finally, on the surface of the flame-retardant and antibacterial layer, quartz sand pretreated with hydrochloric acid and impregnated with KH-570 ethanol solution and dried is mixed with silane coupling agent KH-570 to enhance the adhesion between the flame-retardant and antibacterial layer and the surface protective layer. Then, TD-808 fluorocarbon resin and BP-9200 organosilicon acrylate are compounded in proportion and sprayed in two stages: the first spray is 10-20 μm thick and the pressure is 0.2 MPa; after curing for 30 minutes, the second spray is 10-30 μm thick and the pressure is 0.3 MPa to form the surface protective layer. The protective layer utilizes the compounding properties of fluorocarbon resin and organosilicon acrylate to have excellent chemical corrosion resistance, resist the erosion of various reagents, and further improve the overall fire resistance and durability.

[0030] 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 its spirit or essential characteristics. 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, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. An environmentally friendly formula for a novel fire-resistant and antibacterial decorative panel, characterized in that: It includes a base layer, a flame-retardant and antibacterial layer, a surface protective layer, and a mineral admixture. The flame-retardant and antibacterial layer is coated on the outer surface of the base layer. The base layer is composed of a glass magnesium plate, which contains magnesium oxide, magnesium chloride, and modified volcanic ash. The mineral admixture is a mixture of metakaolin and silica fume in a mass ratio of 3:1, with 5-15 wt% metakaolin added to the base layer.

2. The environmentally friendly formula of a novel fireproof and antibacterial decorative panel according to claim 1, characterized in that: The flame-retardant and antibacterial layer comprises an alginate-based flame retardant, polyhexamethylene sarcosinate, and carbon nanotubes. The polyhexamethylene sarcosinate is loaded with an acrylic emulsion to form a film. The solid content of polyhexamethylene sarcosinate in the flame-retardant and antibacterial layer is 15-25%. The mass ratio of alginate to polyhexamethylene sarcosinate is 1:0.8-1.

2. The carbon nanotubes account for 10-20% of the total mass of the flame-retardant and antibacterial layer.

3. The environmentally friendly formula of a novel fireproof and antibacterial decorative panel according to claim 1, characterized in that: The surface protective layer is composed of TD-808 protective agent and Bp-9200 protective agent in a mass ratio of 1:1 to 2, and has a thickness of 20 to 50 μm. TD-808 protective agent is a water-based fluorocarbon resin, and Bp-9200 protective agent is an organosilicon-modified acrylate. The surface protective layer is applied in two stages by spraying. The thickness of the first spray is 10-20 μm, and the thickness of the second spray is 10-30 μm.

4. The environmentally friendly formula of a novel fireproof and antibacterial decorative panel according to claim 1, characterized in that: The flame-retardant and antibacterial layer and the surface protective layer are mixed with silane coupling agent KH-570 and quartz sand with a particle size of 20-40 mesh, with the quartz sand accounting for 40-60% of the total volume. The quartz sand is pretreated with hydrochloric acid, and the surface roughness Ra is 1.5-2.5 μm. The pretreatment method is to immerse the quartz sand in a 2-5 wt% KH-570 ethanol solution for 30 min and then dry it at 80°C.

5. The environmentally friendly formula of a novel fireproof and antibacterial decorative panel according to claim 2, characterized in that: The alginate is potassium alginate, with a viscosity of 300–800 mPa·s. The carbon nanotubes have a diameter of 10–20 nm and a length of 10–30 nm, forming a continuous network structure in the flame-retardant and antibacterial layer. The flame-retardant region of the flame-retardant and antibacterial layer has a coating thickness of 100–200 μm, and the antibacterial region has a coating thickness of 30–80 μm. Alginate, sodium dihydrogen phosphate, and sodium phosphate were prepared into a solution. Silver nitrate solution was added dropwise and stirred at pH 9-10 and 45°C until a golden yellow gel was formed. The molar ratio of silver nitrate to phosphate was 1:

1. After vacuum degassing, the gel was allowed to stand for 10-20 minutes to form an algae polysaccharide gel solution. Potassium alginate is modified with beeswax by mixing potassium alginate and water at a mass ratio of 1:40-60, dispersing at 70℃, adding 3-5% beeswax (by weight of potassium alginate), homogenizing at 10000r / min for 3-5min, quick-freezing with liquid nitrogen, and then freeze-drying at -40℃ for 8-10h to form a porous modified carrier.

6. The environmentally friendly formula of a novel fireproof and antibacterial decorative panel according to claim 1, characterized in that: The matrix layer comprises, by mass parts, 300-400 parts of modified magnesium oxysulfate cement, 300-400 parts of quartz sand, 50-100 parts of mineral admixture, 3-5 parts of polypropylene fiber, 20-30 parts of inorganic flame retardant and 2-3 parts of water-reducing agent. Take 150-200 parts of quartz sand with a particle size of 20-40 mesh, and take 150-200 parts of quartz sand with a particle size of 40-80 mesh. The inorganic flame retardant is a mixture of aluminum hydroxide and zinc borate in a mass ratio of 5:

1. The flame-retardant and antibacterial layer consists of the following components by mass percentage: 50–80 wt% potassium alginate, 5–15 wt% silver phosphate, 8–20 wt% polyhexamethylene guanidine phosphate, and 2–8 wt% carbon nanotubes. Modified magnesium oxysulfate cement is made by blending industrial by-product gypsum and lightly calcined magnesium oxide in a molar ratio of 1:3, and adding sodium citrate at a mass of 0.5-1% of the cement.

7. The environmentally friendly formula of a novel fireproof and antibacterial decorative panel according to claim 2, characterized in that: The acrylic emulsion has a glass transition temperature of -10 to 5°C, the degree of polymerization of polyhexamethylene sarcosinate is >60, the metakaolin content is 5 to 8% of the total mass of the cementitious material, and the water-cement ratio of the matrix layer is 0.22 to 0.

25. The flame-retardant and antibacterial layer is coated with a calcium borate nanolayer accounting for 0.5-2% of the fiber surface mass. The nascent fibers are sprayed with a 0.1-0.3 wt% boron salt solution 1-3 times. After spraying, the fibers are steam-dried at 95-103℃ for 3-10 minutes. The ratio of boric acid to borax is 4:

1. CO2 gas is introduced during the boron salt solution spraying at a flow rate of 0.5-1 L / min. The humidity is controlled at 70-80% during the steam drying stage.

8. The environmentally friendly formula of a novel fireproof and antibacterial decorative panel according to claim 6, characterized in that: The polyhexamethylene guanidine phosphate and carbon nanotubes form a composite network. A 0.1 wt% polyhexamethylene guanidine phosphate solution and a suspension of potassium alginate and carbon nanotubes are alternately coated onto the substrate layer. Each layer is dried at 60°C after coating. The coating process is repeated 5 to 20 times to form a conductive network on the fiber surface. During the alternating coating process, 0.05 to 0.1 wt% polyvinylpyrrolidone K30 is added to the polyhexamethylene guanidine phosphate solution. After each double layer coating, the electrode is treated with a pulsed electric field for 2 minutes. The distance between the positive and negative electrodes is 10 cm. The electrode plate surface is coated with a polytetrafluoroethylene insulating layer. After the electric field treatment, a graphene oxide coating layer with a thickness of 5 to 10 nm is sputtered onto the surface of the carbon nanotube network. The suspension of potassium alginate and carbon nanotubes was prepared as follows: the potassium alginate solution concentration was 0.1 wt%, the amount of carbon nanotubes added was 1-5% of the mass of sodium alginate, and the suspension was dispersed by ultrasonication at 300W for 30 min and then allowed to stand for 48 h to obtain the stable suspension phase. Before compounding metakaolin and silica fume, mechanical activation treatment is performed. The mixture is then ground in a ball mill with zirconia balls as the medium at a ball-to-material ratio of 5:1 and a rotation speed of 300 r / min for 1 hour. The metakaolin is incorporated as follows: metakaolin with a particle size ≤10μm and a specific surface area ≥20m² / g is premixed with polypropylene and glass fiber in a high-speed mixer at 100-120℃ for 10 minutes to fill pores and consume free Ca(OH)2. When the compound is blended with polypropylene fiber, 0.1-0.5% of an aminated ionic liquid and 0.5% of nano-calcium carbonate nucleating agent by weight of the compound are added.

9. The application of an environmentally friendly formula for a novel fire-resistant and antibacterial decorative panel, applicable to the environmentally friendly formula for a novel fire-resistant and antibacterial decorative panel as described in any one of claims 1-8, characterized in that: The decorative panels are used for hospital operating room walls, laboratory fume hoods, fireproof partitions in high-rise buildings, and ceilings in public transportation waiting halls.

10. The application of the environmentally friendly formula for a novel fire-resistant and antibacterial decorative panel according to claim 9, characterized in that: The decorative panels are also suitable for walls in biosafety laboratories at level P2 and above, and for partitions in cleanrooms with constant temperature and humidity.

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