Wall surface structure based on inorganic epoxy mortar material and construction method thereof

Abstract

The invention discloses a wall surface structure based on an inorganic epoxy mortar material and a construction method thereof.The environment-friendly fireproof wall surface structure comprises a base layer treatment layer, an inorganic epoxy mortar material layer and a surface protection layer, and the side, away from a wall base surface, of the base layer treatment layer is coated with the inorganic epoxy mortar material layer; the surface protection layer covers the side, away from the base layer treatment layer, of the inorganic epoxy mortar material layer. The inorganic epoxy mortar layer is formed by mixing a first component and a second component and then performing a smearing process; the first component is formed by mixing modified inorganic mineral aggregate, colored sand, functional filler and a reinforcing agent according to a preset proportion, the functional filler comprises one or more of hollow microspheres, expanded perlite and inorganic fibers, and the second component is composed of water-borne epoxy resin emulsion and auxiliaries. According to the environment-friendly fireproof wall surface structure, a waterborne epoxy system is adopted, the content of VOCs is extremely low, no pungent smell exists, indoor air pollution can be reduced from the source, and the environment-friendly building standard is met.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, specifically to a wall structure based on inorganic epoxy mortar and its construction method. Background Technology

[0002] Currently, wall decoration materials are a core component affecting the health, safety, and aesthetic experience of the living environment. As people's demands for living quality continue to rise, their requirements for the environmental friendliness, fire safety, functional versatility, and decorative texture of wall materials are becoming increasingly stringent. The limitations of traditional wall decoration materials (such as latex paint, wallpaper, and traditional dry-hanging stone) are becoming increasingly apparent. Existing technologies mainly suffer from the following problems:

[0003] 1. Environmental issues: Many synthetic coatings, wallpaper adhesives and other products widely used in current technology contain volatile organic compounds (VOCs). These substances release harmful gases into the indoor environment over a long period of time during the use of the materials, which damages indoor air quality and has an adverse effect on human health, which is contrary to the current demand for a green and healthy living environment.

[0004] 2. Fire safety issues: Common wall materials such as wallpaper and wooden decorative panels are flammable. In the event of a fire, they not only easily promote the spread of fire, but also produce a large amount of toxic smoke, posing a serious threat to people's escape and life safety. Although traditional dry-hanging stone technology has certain fire resistance, the stone itself is heavy, which places strict requirements on the load-bearing capacity of the wall substrate. Moreover, there is a risk of falling off due to aging of the connection structure during long-term use, which limits its safety and applicability.

[0005] 3. Limited functionality: Existing wall materials generally suffer from limited functionality. Most products focus only on achieving decorative effects and lack the ability to optimize the physical performance of buildings. For example, they cannot effectively achieve functions such as sound absorption and noise reduction, and heat insulation, making it difficult to meet the further demands for improved comfort in living environments.

[0006] 4. Texture and Aesthetics: Imitation stone effects often use colored paint spraying or ceramic tiles, resulting in a hard texture and obvious seams. It is difficult to simulate the natural texture and three-dimensional feel of natural stone, and the construction is complicated and costly.

[0007] In summary, the current wall decoration materials industry urgently needs a new type of wall solution that can simultaneously take into account environmental protection, fire safety, multifunctionality, and high-end decorative texture, while also being easy to install, in order to overcome the many shortcomings of existing technologies and meet the market's urgent demand for a high-quality living environment. Summary of the Invention

[0008] In view of this, the present invention proposes a wall structure based on inorganic epoxy mortar and its construction method to solve at least one defect of existing wall decoration materials in terms of environmental protection, fire safety, functional diversity and decorative texture.

[0009] To achieve the above objectives, the present invention adopts the following technical solution:

[0010] A wall structure based on inorganic epoxy mortar includes a base treatment layer, an inorganic epoxy mortar layer, and a surface protective layer. The inorganic epoxy mortar layer is applied to the side of the base treatment layer facing away from the wall substrate, and the surface protective layer covers the side of the inorganic epoxy mortar layer facing away from the base treatment layer. The inorganic epoxy mortar layer is formed by mixing a first component and a second component in a preset mass ratio and then applying the mixture. The first component is composed of modified inorganic mineral aggregates, colored sand, functional fillers, and reinforcing agents mixed in a preset proportion. The functional fillers include one or more of hollow microspheres, expanded perlite, and inorganic fibers. The second component is composed of water-based epoxy resin emulsion and additives.

[0011] To better achieve the above technical solution, optionally, the inorganic mineral aggregate is 40-60 mesh quartz sand, the colored sand is 80-120 mesh natural calcined colored sand, and the reinforcing agent is ordinary Portland cement with a strength grade of not less than 42.5.

[0012] Optionally, the additives include at least one of defoamers and dispersants.

[0013] Optionally, the first component is composed of the following parts by weight: 50 parts of 40-60 mesh quartz sand, 30 parts of 80-120 mesh natural calcined colored sand, 5 parts of expanded perlite, and 15 parts of ordinary silicate cement; the second component is composed of the following parts by weight: 20 parts of water-based epoxy resin emulsion, 0.5 parts of defoamer, and 0.5 parts of dispersant; and the mass ratio of the first component to the second component is (3-5):1.

[0014] A wall structure based on inorganic epoxy mortar and its construction method include the following steps:

[0015] S10. Base treatment: Clean the concrete wall base surface of floating dust, oil stains and loose attachments until the solid base is exposed. Use cement mortar to level the holes, depressions and uneven areas of the wall surface. After the leveling layer has been naturally cured to a compressive strength ≥15MPa, roll on a layer of epoxy special sealing primer and let it stand to cure until the primer is completely dry.

[0016] S20. Slurry preparation: The slurry is prepared by mixing the first component and the second component according to any one of claims 1 to 4. In a mixing container, the second component is added first and stirred at a low speed of 80-120 r / min. Then, while continuing to stir at a low speed, the pre-mixed dry powder of the first component is gradually added. After the addition is completed, the stirring speed is increased to 180-220 r / min and stirred for 5-10 minutes to form a paste-like putty with uniform color and no dry powder particles. Let it stand for 3-4 minutes until there is no layering.

[0017] S30, Thick troweling: Use a trowel to take the slurry prepared in step S20 and evenly apply a thin layer to the wall base surface treated in step S10 as a base coat. After the base coat has been left to stand for 5-10 minutes until it is no longer sticky to the touch, take the slurry for thick troweling. During the thick troweling process, control the thickness of each application to not exceed 5mm. After the total thickness reaches the preset value, use a smooth trowel to smooth and compact the slurry in the same direction before it is surface dry to ensure that the surface is free of pores and air bubbles.

[0018] S40. Curing and maintenance: After construction, control the temperature of the curing environment to 20-30℃ and the relative humidity to ≤75%. Avoid vibration or external impact on the wall surface. Spray deionized water on the surface 1-2 times a day for the first 3 days to keep it moist. Then, allow it to cure naturally for 7 days to achieve complete curing.

[0019] S50 Surface Protection: Select a transparent inorganic silane protective agent and apply the first layer by roller coating or airless spraying. After the protective agent has dried to the touch, apply the second layer with the same amount of coating. After the second layer is applied, allow it to cure until a dense and uniform antifouling protective film is formed.

[0020] To better achieve the above technical solution, optionally, in step S20, the mass ratio of the first component to the second component is (3-4):1.

[0021] Optionally, in step S30, the thick plastering construction adopts a "one-tight-one-release" plastering technique. When pulling back the trowel, the slurry is compacted along the 45° direction, and when releasing the trowel, the slurry is spread along the 30° direction. The angle between the trowel and the wall surface is controlled at 30°-60°. Through scraping, rubbing and troweling operations, random cracks and undulating textures that resemble natural stone are formed.

[0022] To better achieve the above technical solution, optionally, the thickness of the base coat is controlled to be 1-2mm and completely covers the surface of the base treatment layer, the total thickness of the thick coat is controlled to be 5-8mm, and it is applied in 3-4 coats, with the first coat being 3-4mm thick and the remaining thickness applied after an interval of 20-30 minutes.

[0023] The beneficial effects of this invention are:

[0024] This invention discloses a wall structure based on inorganic epoxy mortar, using a water-based epoxy system as the bonding matrix. It has extremely low VOC content, no irritating odor, and can reduce indoor air pollution at the source, meeting green building standards. The inorganic epoxy mortar primarily uses inorganic mineral aggregates, which are non-combustible and possess high-temperature resistance. In the event of fire, the mortar will not produce toxic or harmful fumes, meeting the safety requirements for wall decoration materials in building fire protection codes. The porous structure of the natural calcined colored sand in the inorganic epoxy mortar synergistically combines with the lightweight and porous characteristics of expanded perlite to effectively absorb sound wave energy from the environment, reduce indoor reverberation, and improve indoor acoustic comfort. The inorganic epoxy mortar and the concrete wall substrate form a reliable interface bond through a special epoxy sealing primer, resulting in strong wall integrity and effectively preventing problems such as hollowing and detachment after construction. After curing, the mortar has high mechanical strength and good wear resistance, chemical corrosion resistance, and weather resistance, adapting to different usage environments and extending the service life of the wall structure. Compared to traditional dry-hanging stone construction, this wall structure does not require additional metal hangers, keels, or other supporting components, reducing the additional load on the wall. The application of a coating process simplifies the process, is more adaptable to the flatness of the base wall surface, and eliminates the need for complex stone cutting and splicing procedures, thus reducing material waste and construction costs, resulting in better overall economic efficiency.

[0025] This invention discloses a wall structure construction process based on inorganic epoxy mortar. By applying it manually or using special tools, it can replicate the original texture of natural stone materials such as granite, marble, and sandstone. The resulting decorative surface layer has a continuous and seamless texture, and its surface feel is highly consistent with that of natural stone. Combined with the color characteristics of natural calcined colored sand, the texture and color of the decorative surface layer can be adjusted according to design requirements, resulting in a highly personalized decorative effect that can meet the needs of diverse architectural decoration styles. Attached Figure Description

[0026] Figure 1 This is a schematic flowchart of a wall structure construction method based on inorganic epoxy mortar according to Embodiment 2 of the present invention. Detailed Implementation

[0027] The technical solution of the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. Identical components are indicated by the same reference numerals.

[0028] Example 1

[0029] A wall structure based on inorganic epoxy mortar includes a base treatment layer, an inorganic epoxy mortar layer, and a surface protective layer.

[0030] The base treatment layer is an epoxy-specific sealing primer, forming a sealed protective film on the concrete wall surface. This film provides mechanical anchoring and sealing, while also preventing the leaching of alkaline and salt substances. An inorganic epoxy mortar layer is applied to the side of the base treatment layer facing away from the wall surface, and a surface protective layer covers the same side. The inorganic epoxy mortar layer is formed by mixing the first and second components in a preset mass ratio and then applying them through a coating process. The first component is composed of modified inorganic mineral aggregates, colored sand, functional fillers, and reinforcing agents mixed in a preset proportion. The functional fillers include one or more of hollow microspheres, expanded perlite, and inorganic fibers. The second component consists of water-based epoxy resin emulsion and additives.

[0031] In the embodiments of the present invention, the inorganic mineral aggregate is 40-60 mesh quartz sand, the colored sand is 80-120 mesh natural calcined colored sand, the reinforcing agent is ordinary silicate cement with a strength grade of not less than 42.5, and the additives include at least one of defoamer and dispersant. The defoamer is one or more of mineral oils and organosilicon compounds, such as polydimethylsiloxane. By adding the defoamer, foam can be suppressed or eliminated during the preparation of inorganic epoxy mortar. The dispersant is unsaturated fatty acid polyamine amide. By adding the dispersant, solid particles can be dispersed to achieve slurry uniformity.

[0032] In an embodiment of the present invention, the first component is composed of the following parts by weight: 50 parts of 40-60 mesh quartz sand, 30 parts of 80-120 mesh natural calcined colored sand, 5 parts of expanded perlite, and 15 parts of ordinary silicate cement; the second component is composed of the following parts by weight: 20 parts of water-based epoxy resin emulsion, 0.5 parts of defoamer, and 0.5 parts of dispersant; and the mass ratio of the first component to the second component is (3-5):1.

[0033] This invention discloses a wall structure based on inorganic epoxy mortar, using a water-based epoxy system as the bonding matrix. It has extremely low VOC content, no irritating odor, and can reduce indoor air pollution at the source, meeting green building standards. The inorganic epoxy mortar primarily uses inorganic mineral aggregates, which are non-combustible and possess high-temperature resistance. In the event of fire, the mortar will not produce toxic or harmful fumes, meeting the safety requirements for wall decoration materials in building fire protection codes. The porous structure of the natural calcined colored sand in the inorganic epoxy mortar synergistically combines with the lightweight and porous characteristics of expanded perlite to effectively absorb sound wave energy from the environment, reduce indoor reverberation, and improve indoor acoustic comfort. The inorganic epoxy mortar and the concrete wall substrate form a reliable interface bond through a special epoxy sealing primer, resulting in strong wall integrity and effectively preventing problems such as hollowing and detachment after construction. After curing, the mortar has high mechanical strength and good wear resistance, chemical corrosion resistance, and weather resistance, adapting to different usage environments and extending the service life of the wall structure. Compared to traditional dry-hanging stone construction, this wall structure does not require additional metal hangers, keels, or other supporting components, reducing the additional load on the wall. The application of a coating process simplifies the process, is more adaptable to the flatness of the base wall surface, and eliminates the need for complex stone cutting and splicing procedures, thus reducing material waste and construction costs, resulting in better overall economic efficiency.

[0034] Example 2

[0035] Please see Figure 1 This invention discloses a wall structure construction method based on inorganic epoxy mortar, characterized by comprising the following steps:

[0036] S10. Base treatment: Clean the concrete wall base surface of floating dust, oil stains and loose attachments until the solid base is exposed. Use cement mortar to level the holes, depressions and uneven areas of the wall surface. After the leveling layer has been naturally cured to a compressive strength ≥15MPa, roll on a layer of epoxy special sealing primer and let it stand to cure until the primer is completely dry.

[0037] In step S10, the flatness error of the leveled wall base surface is ≤3mm / 2m, and the epoxy special sealing primer is applied at 100-150g / ㎡.

[0038] S20. Slurry preparation: The slurry is prepared by mixing the first component and the second component according to any one of claims 1 to 4. In a mixing container, the second component is added first and stirred at a low speed of 80-120 r / min. Then, while continuing to stir at a low speed, the pre-mixed dry powder of the first component is gradually added. After the addition is completed, the stirring speed is increased to 180-220 r / min and stirred for 5-10 minutes to form a paste-like putty with uniform color and no dry powder particles. Let it stand for 3-4 minutes until there is no layering.

[0039] In step S20, the mass ratio of the first component to the second component is (3-4):1. The higher the proportion of the first component, the higher the consistency of the inorganic epoxy mortar. Preferably, the mass ratio of the first component to the second component is 3:1, which results in a moderate consistency of the inorganic epoxy mortar.

[0040] S30, Thick troweling: Use a trowel to take the slurry prepared in step S20 and evenly apply a thin layer to the wall base surface treated in step S10 as a base coat. After the base coat has been left to stand for 5-10 minutes until it is no longer sticky to the touch, take the slurry for thick troweling. During the thick troweling process, control the thickness of each application to not exceed 5mm. After the total thickness reaches the preset value, use a smooth trowel to smooth and compact the slurry in the same direction before it is surface dry to ensure that the surface is free of pores and air bubbles.

[0041] In step S30, the thick plastering process uses a "one-tight-one-release" plastering technique. When tightening the plaster, press the plaster along a 45° direction, and when releasing the plaster, spread the plaster along a 30° direction. The angle between the plaster and the wall is controlled between 30° and 60°. Through scraping, rubbing, and plastering operations, random cracks and undulating textures that resemble natural stone are formed.

[0042] In step S30, the thickness of the base coat is controlled to be 1-2mm and completely covers the surface of the base treatment layer. The total thickness of the thick coat is controlled to be 5-8mm and is applied in two coats. The first coat is 3-4mm thick, and the remaining thickness is applied after an interval of 20-30 minutes.

[0043] S40. After construction, control the curing environment temperature to 20-30℃ and relative humidity to ≤75%. Avoid vibration or external impact on the wall surface. Spray deionized water on the surface 1-2 times a day for the first 3 days to keep it moist. Then allow it to cure naturally for 7 days to achieve complete curing.

[0044] S50 Surface Protection: Select a transparent inorganic silane protective agent and apply the first layer by roller coating or airless spraying. After the protective agent has dried to the touch, apply the second layer with the same amount of coating. After the second layer is applied, allow it to cure until a dense and uniform antifouling protective film is formed.

[0045] This invention discloses a wall structure construction process based on inorganic epoxy mortar. By applying it manually or using special tools, it can replicate the original texture of natural stone materials such as granite, marble, and sandstone. The resulting decorative surface layer has a continuous and seamless texture, and its surface feel is highly consistent with that of natural stone. Combined with the color characteristics of natural calcined colored sand, the texture and color of the decorative surface layer can be adjusted according to design requirements, resulting in a highly personalized decorative effect that can meet the needs of diverse architectural decoration styles.

[0046] The technical solution of the present invention has been described in detail above with reference to specific embodiments. The specific embodiments described are used to help understand the concept of the present invention. Derivations and modifications made by those skilled in the art based on the specific embodiments of the present invention also fall within the scope of protection of the present invention.

Claims

1. A wall structure based on inorganic epoxy mortar, comprising a base treatment layer, characterized in that, It also includes an inorganic epoxy mortar layer and a surface protective layer. The inorganic epoxy mortar layer is applied to the side of the base treatment layer away from the wall surface, and the surface protective layer covers the side of the inorganic epoxy mortar layer away from the base treatment layer. The inorganic epoxy mortar layer is formed by mixing a first component and a second component in a preset mass ratio and then applying the mixture. The first component is composed of modified inorganic mineral aggregates, colored sand, functional fillers, and reinforcing agents mixed in a preset ratio. The functional fillers include one or more of hollow microspheres, expanded perlite, and inorganic fibers. The second component is composed of water-based epoxy resin emulsion and additives.

2. The wall structure based on inorganic epoxy mortar according to claim 1, characterized in that, The inorganic mineral aggregate is 40-60 mesh quartz sand, the colored sand is 80-120 mesh natural calcined colored sand, and the reinforcing agent is ordinary silicate cement with a strength grade of not less than 42.

5.

3. A wall structure based on inorganic epoxy mortar according to claim 2, characterized in that, The additives include at least one of defoamers and dispersants.

4. A wall structure based on inorganic epoxy mortar according to claim 3, characterized in that, The first component is composed of the following parts by weight: 50 parts of 40-60 mesh quartz sand, 30 parts of 80-120 mesh natural calcined colored sand, 5 parts of expanded perlite, and 15 parts of ordinary silicate cement; the second component is composed of the following parts by weight: 20 parts of water-based epoxy resin emulsion, 0.5 parts of defoamer, and 0.5 parts of dispersant; and the mass ratio of the first component to the second component is (3-5):

1.

5. A wall structure based on inorganic epoxy mortar and its construction method, characterized in that, Includes the following steps: S10. Base treatment: Clean the concrete wall base surface of floating dust, oil stains and loose attachments until the solid base is exposed. Use cement mortar to level the holes, depressions and uneven areas of the wall surface. After the leveling layer has been naturally cured to a compressive strength ≥15MPa, roll on a layer of epoxy special sealing primer and let it stand to cure until the primer is completely dry. S20. Slurry preparation: The slurry is prepared by mixing the first component and the second component according to any one of claims 1 to 4. In a mixing container, the second component is added first and stirred at a low speed of 80-120 r / min. Then, while continuing to stir at a low speed, the pre-mixed dry powder of the first component is gradually added. After the addition is completed, the stirring speed is increased to 180-220 r / min and stirred for 5-10 minutes to form a paste-like putty with uniform color and no dry powder particles. Let it stand for 3-4 minutes until there is no layering. S30, Thick troweling: Use a trowel to take the slurry prepared in step S20 and evenly apply a thin layer to the wall base surface treated in step S10 as a base coat. After the base coat has been left to stand for 5-10 minutes until it is no longer sticky to the touch, take the slurry for thick troweling. During the thick troweling process, control the thickness of each application to not exceed 5mm. After the total thickness reaches the preset value, use a smooth trowel to smooth and compact the slurry in the same direction before it is surface dry to ensure that the surface is free of pores and air bubbles. S40. Curing and maintenance: After construction, control the ambient temperature of the curing environment to 20-30℃ and the relative humidity to ≤75%. Avoid vibration or external impact on the wall surface. Spray deionized water on the surface 1-2 times a day for the first 3 days to keep it moist. Then, allow it to cure naturally for 7 days to achieve complete curing. S50 Surface Protection: Select a transparent inorganic silane protective agent and apply the first layer by roller coating or airless spraying. After the protective agent has dried to the touch, apply the second layer with the same amount of coating. After the second layer is applied, allow it to cure until a dense and uniform antifouling protective film is formed.

6. A wall structure based on inorganic epoxy mortar according to claim 5, characterized in that, In step S20, the mass ratio of the first component to the second component is (3-4):

1.

7. A wall structure based on inorganic epoxy mortar according to claim 6, characterized in that, In step S30, the thick plastering process uses a "one-tight-one-release" plastering technique. When tightening the plaster, press the plaster along a 45° direction, and when releasing the plaster, spread the plaster along a 30° direction. The angle between the plaster and the wall is controlled between 30° and 60°. Through scraping, rubbing, and troweling operations, random cracks and undulating textures that resemble natural stone are formed.

8. A wall structure based on inorganic epoxy mortar according to claim 6, characterized in that, The thickness of the base coat is controlled to be 1-2mm and completely covers the surface of the base treatment layer. The total thickness of the thick coat is controlled to be 5-8mm and is applied in 3-4 coats. The first coat is 3-4mm thick, and the remaining thickness is applied after an interval of 20-30 minutes.

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