TWI898851B - Low carbon footprint stone-like coating and main material thereof - Google Patents

Abstract

A low carbon footprint stone-like coating is suitable for application on a substrate and comprises a primer layer for adhering to the substrate, a main material layer that is directly or indirectly attached to the primer layer to provide a stone-like texture, and a topcoat layer applied over the main material layer for protection. The main material layer includes an inorganic aggregate, which is a silicate obtained from recycled silicon-containing waste. This low carbon footprint stone-like coating is more environmentally friendly, has a reduced carbon footprint, and offers higher hardness and improved wear resistance.

Description

Low-carbon footprint imitation stone coating and its main materials

This project is about a stone-like coating, specifically a low-carbon stone-like coating.

While stone is a popular building material for many Taiwanese, concerns about its non-renewable nature, such as the waste costs and natural resources it causes, as well as the excessive weight it places on building structures, are gradually being addressed, prompting the search for alternatives.

Early "washed gravel" construction methods primarily involved mixing natural stone with cement and stirring thoroughly. Workers then applied the mixture evenly to building walls or floors with a spatula. Once the cement-natural stone mixture dried slightly and solidified, it was scrubbed with a sponge or sprayed with pressurized water mist. The time-consuming and labor-intensive application process increased construction costs. The post-application scrubbing or flushing step required to remove excess sludge, significantly increasing the overall process complexity and making the work relatively cumbersome. The final scrubbing or flushing step also generated significant wastewater, polluting the construction site and making it less environmentally friendly.

To solve the above-mentioned problem, some manufacturers have developed sprayable imitation stone coatings, such as the imitation stone coating disclosed in the conventional technology publication No. TW201249671A. Figure 1 shows the formula and flow chart of the imitation stone coating of conventional technology. As shown in Figure 1, it is mainly made by mixing a resin (91), a seaweed (92), a water (93), a stone powder (94), a sand (95), a cement (96), and a plurality of multi-color flakes (97). After spraying, the multi-color flakes (97) are staggered or layered to create a natural stone texture with irregular surface patterns.

However, although the above-mentioned conventional technology can achieve the effect of imitating stone appearance, the components of the conventional technology are not renewable resources, nor are they waterproof and weather-resistant. In addition, the multi-color sheet (97) is limited in size, and the resolution of the imitation stone effect is limited, resulting in a relatively low degree of realism.

Given these and other issues, there is still room for improvement in existing technologies.

To address these and other issues, the main purpose of this invention is to provide a low-carbon footprint-like stone coating to improve upon previous technologies.

One of the goals of this project is to provide a low-carbon footprint imitation stone coating. Its inorganic aggregate is recycled from silicon-containing waste, making it more environmentally friendly and low-carbon.

Another purpose of this invention is to provide a low-carbon footprint imitation stone coating with higher hardness and higher wear resistance.

Another goal of this invention is to provide a low-carbon, imitation stone-like coating with a base coat of adhesive resin. It can be evenly applied to building walls or floors without a scraper, thus reducing application costs compared to previous technologies.

Another goal of this project is to provide a low-carbon footprint-like stone coating with an acrylic resin mid-coat that offers improved durability and toughness compared to previous technologies.

Another goal of this project is to provide a low-carbon footprint-like stone coating, using a primary spray coating consisting of pigment paste and inorganic aggregate (white sand) to enhance the fidelity of the stone-like finish compared to previous technologies.

Another goal of this project is to provide a low-carbon, footprint-like stone coating that can be adapted to the substrate's texture to close the substrate's pores, reduce dust impact, and minimize capillary effects.

To achieve the aforementioned and other invention objectives, the present invention provides a low-carbon footprint imitation stone coating suitable for application to a substrate, comprising: a primer layer for adhering to the substrate; a primary material layer applied over the primary layer to provide a simulated stone texture; and a paint layer applied over the primary material layer to protect it. The primary material layer comprises an inorganic aggregate, which is a silicide or silicon dioxide obtained by reprocessing or recycling silicon-containing waste.

Preferably, the primer layer can be formulated to suit the substrate and can be either transparent or colored.

In one embodiment, the inorganic aggregate is spherical silica obtained from reprocessed or recycled silicon-containing waste. Preferably, the spherical silica can be obtained directly from the silicon-containing waste through a single treatment, eliminating the need for secondary or tertiary carbonization (which would increase carbon emissions). Preferably, the spherical silica obtained after reprocessing has a diameter between 3 and 30 μm. Preferably, the reprocessing temperature is between 850 and 1350°C. Reprocessing conditions may affect the whiteness or hardness of the silicide or silica. Therefore, appropriate processing conditions must be selected or adjusted based on the substrate on which the imitation stone coating is applied.

In one embodiment, the particle size of the spherical silica is approximately 10-15 μm, and the sphericity of the spherical silica is ≥80%.

In one embodiment, the inorganic aggregate is silicon carbide obtained by reprocessing the silicon-containing waste.

In one embodiment, the main material layer comprises approximately 0% to 10% by weight of a color paste, approximately 5% to 65% by weight of an inorganic aggregate, and approximately 5% to 35% by weight of a resin.

In one embodiment, the main material layer further comprises sufficient water.

In one embodiment, the paste is composed of a color matching a simulated stone object.

In one embodiment, the primer layer contains an adhesive resin selected from polyurethane, ethylene vinyl acetate copolymer, polyurethane acrylate, polyacrylate, and epoxy resin.

In one embodiment, the primer layer has alkali resistance for adhesion to the substrate including new substrates and old substrates.

In one embodiment, a mid-coat layer is further included, applied on the primer layer, so that the main material layer can be applied on the mid-coat layer.

In one embodiment, when the primer layer is transparent, the mid-coat layer contains the inorganic aggregate.

In one embodiment, the mid-coat layer contains acrylic resin. The mid-coat layer has high toughness properties, which is used to improve the bonding durability between the primer layer and the main material layer.

In one embodiment, the topcoat layer has waterproof, scratch-resistant, alkali-resistant and UV-resistant properties.

In one embodiment, the substrate comprises glass, cement, metal, steel, calcium silicate plate, ceramic tile, kiln-fired plate, stone plate or other imitation stone plate.

To achieve the aforementioned and other objectives of the invention, this invention further provides a main material for a low-carbon footprint imitation stone coating, which is used to provide a stone-like texture. The main material comprises an inorganic aggregate, which is a silicide obtained by reprocessing silicon-containing waste.

In one embodiment, the inorganic aggregate is spherical silica obtained by reprocessing the silicon-containing waste, with a diameter of 3-30 μm and a reprocessing temperature of 850-1350°C.

In one embodiment, the particle size of the spherical silica is approximately 10-15 μm, and the sphericity of the spherical silica is ≥80%.

In one embodiment, the inorganic aggregate is silicon carbide obtained by reprocessing the silicon-containing waste.

In one embodiment, the main material comprises approximately 0% to 10% by weight of a color paste, approximately 5% to 65% by weight of an inorganic aggregate, and approximately 5% to 35% by weight of a resin.

In one embodiment, the main material complies with the requirements of the Green Building Materials Label.

Directions described herein, or terms similar to them, such as front, back, left, right, top, bottom, inside, outside, and side, primarily refer to the directions in the drawings and are intended solely to facilitate description and understanding of the various embodiments of this invention and are not intended to limit this invention. Furthermore, the use of articles such as "a" or "the" to refer to elements or components herein is intended solely for simplicity and should be construed to include one or at least one, and the singular also encompasses the plural unless otherwise expressly indicated.

[This creation]

(W): Base material

(11): Primer layer

(12): Middle coating layer

(13): Main material layer

(131): Color paste

(132):Inorganic aggregate

(133):Resin

(14): Topcoat layer

(S21, S22, S23, S24): Steps

[Practice]

(91):Resin

(92):Seaweed

(93): Water

(94): Stone powder

(95):Sand

(96): Cement

(97):Multi-color film

The implementation of this invention will be described with the following simple explanation and diagrams: Figure 1 is the formula and flow chart of the stone-like coating using conventional technology.

Figure 2 is a schematic diagram of the low-carbon footprint imitation stone coating of this creative embodiment.

Figure 3 is an electron microscope magnified image of silicon dioxide in an embodiment of this invention.

Figure 4 is a schematic diagram of the construction process of the low-carbon footprint imitation stone coating of this creative embodiment.

To make the above and other purposes, features, and advantages of this invention more clearly understood, preferred embodiments are described below in detail with accompanying drawings. Items designated by the same symbols in different drawings may be considered identical and their descriptions may be omitted.

FIG2 is a schematic diagram of the low-carbon footprint imitation stone coating of the present invention. Referring to FIG2, the low-carbon footprint imitation stone coating of the present invention is suitable for a substrate (W). The low-carbon footprint imitation stone coating of the present invention comprises: a primer layer (11) for adhering to the substrate (W); a main material layer (13) applied on the upper layer to provide an imitation stone texture; and a paint layer (14) applied on the main material layer (13) to protect the main material layer (13), wherein the main material layer (13) comprises an inorganic aggregate (132), which is a silicide or silicon dioxide obtained by recycling silicon-containing waste.

As an important semiconductor manufacturing center in the world, Taiwan has a very high demand for silicon dioxide. Correspondingly, the amount of silicon-containing waste generated is also very considerable. The inorganic aggregate (132) is very helpful to the protection of the earth's ecology by recycling and treating silicon-containing waste.

Preferably, the inorganic aggregate (132) is spherical silica obtained by recycling silicon-containing waste, with a diameter of 3 to 30 μm and a processing temperature of 850 to 1350°C. In this way, the desired silica is refined.

The spherical silica is a fine nano-scale material with a particle size of approximately 10-15μm and a true sphericity of ≥80%. Through practical application, its flexural strength has been increased from 14.2MPa to 34.4MPa compared to the original material, and its refractoriness can reach SK29 (1650°C) and above, effectively improving the overall material performance.

Table 1 below compares the materials used in the examples and comparative examples of this invention. As can be seen from Table 1, Comparative Example B is too large, and Comparative Example C is too small.

Another embodiment of this invention is A1, as shown in Table 2 below.

This creative embodiment is also A2 material, as shown in Table 3 below.

Specific surface area (SSA) refers to the total surface area per unit mass of a solid. The specific surface area of a material is measured using the BET (Brunauer Emmett Teller) instrument and gas adsorption techniques. A high specific surface area helps improve the structural strength of a material because more surface area provides more binding or reaction sites, making the material's structure more compact. As shown in Tables 1-3, material A2 has an optimal specific surface area of 0.8-1.3 ^m² /g.

The silica purity of A2 material is >98.5%. High-purity silica means there are almost no other impurities in the material, which helps improve the structural strength and stability of the material. High-purity silica can provide better mechanical strength and chemical resistance.

Therefore, compared with other materials, the inorganic aggregate (132) made of A2 material has a higher specific surface area and higher purity silicon dioxide, which enables the inorganic aggregate (132) to have a better structure.

In addition, since the inorganic aggregate (132) is obtained from silicon-containing waste after recycling, the inorganic aggregate (132) has undergone at least two processes, including: the first production of silicon-containing products and the second recycling process. The inorganic aggregate (132) after the secondary processing has better hardness, and its principle is close to that of silicon carbide. The Mohs hardness of silicon carbide (SiC) is about 9, second only to diamond and boron carbide, and has high hardness and high wear resistance. Silicon carbide material has stable chemical and mechanical properties. Its low energy consumption, high power, high temperature resistance, corrosion resistance and wear resistance make it one of the popular third-generation semiconductor materials.

Preferably, the main material layer (13) comprises a color paste (131) of about 0% to 10% by weight, an inorganic aggregate (132) of about 5% to 65% by weight, and a resin (133) of about 5% to 35% by weight. Thus, the material can imitate stone while also possessing other properties such as high hardness, high temperature resistance, and wear resistance.

More preferably, the main material layer (13) further contains sufficient water to ensure that the main material layer (13) has a certain degree of fluidity so that it can be sprayed with a spray gun.

More preferably, the color paste (131) is composed of the color matching of a simulated stone object, and the computer first analyzes the color matching ratio of the simulated stone object, and then uses the color paste (131) to imitate the color and texture of the simulated stone object.

Preferably, the primer layer (11) contains an adhesive resin selected from polyurethane, ethylene vinyl acetate copolymer, polyurethane acrylate, polyacrylate, and epoxy resin. Thus, the diverse physical properties can be used in different environments, and the excellent adhesion performance ensures good adhesion between the primer layer (11) and the subsequent coating or the substrate (W), thereby enhancing the overall durability and performance.

More preferably, the primer layer (11) has strong alkali resistance for adhering to the substrate (W) including new and old substrates. Since the main component of cement and concrete is calcium oxide, a highly alkaline substance with a pH value generally higher than 12, in a humid environment or in contact with water, the cement will release calcium hydroxide during the reaction process with water, forming a strong alkaline environment on the wall surface. Without strong alkali resistance, the protective performance will be reduced and structural problems will occur due to reduced adhesion, incomplete hardening and chemical degradation caused by alkalinity.

Preferably, it further comprises a middle coating layer (12) applied on the primer layer (11) so that the main material layer (13) can be applied on the middle coating layer (12). In this way, the base color is applied and the durability and toughness are improved.

More preferably, when the primer layer (11) is transparent, the mid-coat layer (12) includes the inorganic aggregate (132). This provides a background color for the imitation stone on the substrate (W) to prevent the main material layer (13) from being unable to cover the original color of the substrate (W).

More preferably, the middle coating layer (12) contains acrylic resin, and the middle coating layer (12) has high toughness properties to improve the bonding durability of the primer layer (11) and the main material layer (13). In this way, cracks in the coating layer caused by expansion or contraction are reduced.

Preferably, the topcoat layer (14) has waterproof, scratch-resistant, alkali-resistant and UV-resistant properties. This can prevent adverse effects caused by harsh environments such as strong winds and heavy rain, flying sand and rocks, extreme cold and heat, and scorching sun.

Preferably, the substrate (W) comprises glass, cement, metal, steel, calcium silicate plate, tile, kiln-fired plate, stone plate or other imitation stone plate. This covers most common building surface materials.

Preferably, the main material of the low-carbon footprint imitation stone coating, used to provide a simulated stone texture, comprises an inorganic aggregate, which is a silicide obtained by reprocessing silicon-containing waste. This achieves the environmentally friendly goal of resource reuse.

More preferably, the inorganic aggregate is spherical silica obtained by reprocessing the silicon-containing waste, with a diameter of 3-30 μm and a reprocessing temperature of 850-1350°C. The desired silica is thereby refined.

More preferably, the spherical silica has a particle size of approximately 10-15 μm and a true sphericity of ≥80%. This improves fluidity and uniformity, enhances material performance, and enhances durability.

More preferably, the inorganic aggregate is silicon carbide obtained by reprocessing the silicon-containing waste. This allows the inorganic aggregate to possess high hardness, high temperature resistance, corrosion resistance, and wear resistance.

More preferably, the main material comprises approximately 0% to 10% by weight of pigment, approximately 5% to 65% by weight of inorganic aggregate, and approximately 5% to 35% by weight of resin. This allows the material to mimic stone while also possessing other properties such as high hardness, high temperature resistance, and wear resistance.

Preferably, the main material complies with the Green Building Materials Standard. This addresses the government's Green Building Materials Standard objectives, namely: 1. Green building materials are environmentally friendly, ensuring that Green Building Materials Standard products have low environmental impact at all stages of their life cycle; 2. Green building materials are human-friendly, ensuring they pose no risk to human health; and 3. Green building materials must meet relevant specifications and standards, ensuring their quality meets both regulatory and general functional requirements.

FIG3 is an electron microscope magnified image of silicon dioxide according to an embodiment of the present invention. Refer to Figure 3. Using a scanning electron microscope (SEM), a type of electron microscope that produces surface images by scanning a sample with a focused electron beam, the appearance of this spherical silica is magnified. With a true sphericity of ≥80%, the appearance is different from typical silica. Natural quartz silica exists in crystalline form, with a hexagonal or hexahedral structure. Common sand, also silica, is typically irregular in shape with rough edges. Because this spherical silica is close to a true sphere and is minute in size, it possesses a high specific surface area. This greater surface area provides more bonding or reaction sites, making the material's structure more compact.

FIG4 is a schematic diagram of the construction process of the low-carbon footprint imitation stone coating of the present invention. Referring to FIG4, the low-carbon footprint imitation stone coating of the present invention is suitable for use on a substrate (W) such as a building wall or ground. The construction method thereof includes: (S21) applying a primer layer (11) on the substrate (W) using a brush, roller or spray gun; (S22) applying a mid-coat layer (12) on the primer layer (11) using a spray gun; (S23) applying a main material layer (13) on the mid-coat layer (12) using a spray gun; (S24) applying a topcoat layer (14) on the main material layer (13) using a brush, roller or spray gun.

Although this invention has been disclosed using the preferred embodiments described above, they are not intended to limit this invention. Any changes and modifications made by anyone skilled in the art, without departing from the spirit and scope of this invention, to the aforementioned embodiments are still within the technical scope protected by this invention. Therefore, the scope of protection of this invention includes all modifications within the meaning and equivalent scope of the appended patent applications. If the aforementioned embodiments can be combined, this invention includes any combination of implementations.

(W): Base material

(11): Primer layer

(12): Middle coating layer

(13): Main material layer

(131): Color paste

(132):Inorganic aggregate

(133):Resin

(14): Topcoat layer

Claims (20)

A low-carbon footprint imitation stone coating is suitable for a substrate (W), comprising: a primer layer (11) for adhering to the substrate (W); a main material layer (13) directly or indirectly attached to the primer layer (11) for providing an imitation stone texture; and a paint layer (14) attached to the main material layer (13) for protecting the main material layer (13), wherein the main material layer (13) comprises an inorganic aggregate (132), which is a silicide obtained by reprocessing silicon-containing waste. The low-carbon footprint imitation stone coating as described in claim 1, wherein the inorganic aggregate (132) is spherical silica obtained by reprocessing the silicon-containing waste, and the average particle size is between 3 and 30 μm. The low-carbon footprint imitation stone coating as described in claim 2, wherein the D50 particle size of the spherical silica is approximately 20 μm. The low-carbon footprint imitation stone coating as described in claim 1, wherein the inorganic aggregate (132) is silicon carbide obtained by reprocessing the silicon-containing waste. The low-carbon footprint imitation stone coating as described in claim 1, wherein the main material layer (13) comprises a color paste (131) with a weight percentage of approximately 0% to 10%, an inorganic aggregate (132) with a weight percentage of approximately 5% to 65%, and a resin (133) with a weight percentage of approximately 5% to 35%. The low-carbon footprint imitation stone coating as described in claim 5, wherein the main material layer (13) further contains sufficient water. A low-carbon footprint imitation stone coating as described in claim 5, wherein the color paste (131) is composed of a color matching of a stone imitation object. The low-carbon footprint imitation stone coating as described in claim 1, wherein the primer layer (11) contains an adhesive resin, and the adhesive resin is selected from one of polyurethane, ethylene vinyl acetate copolymer, polyurethane acrylate, polyacrylate, and epoxy resin. The low-carbon footprint imitation stone coating as described in claim 1, wherein the primer layer (11) has strong alkali resistance and is used to adhere to the substrate (W) containing new and old materials. The low-carbon footprint imitation stone coating as described in claim 1 further comprises a middle coating layer (12) attached to the primer layer (11) so that the main material layer (13) is indirectly attached to the middle coating layer (12). The low-carbon footprint imitation stone paint as described in claim 10, wherein when the primer layer (11) is transparent, the mid-coat layer (12) contains the inorganic aggregate (132). The low-carbon footprint imitation stone coating as described in claim 10, wherein the middle coating layer (12) contains acrylic resin, and the middle coating layer (12) has high toughness properties to improve the bonding durability of the primer layer (11) and the main material layer (13). The low-carbon footprint imitation stone coating as described in claim 1, wherein the topcoat layer (14) has waterproof, scratch-resistant, alkali-resistant and UV-resistant properties. The low-carbon footprint imitation stone coating as described in claim 1, wherein the substrate (W) comprises glass, cement, metal, steel, calcium silicate plate, tile, kiln-fired plate, stone plate or other imitation stone plate. A main material of a low-carbon footprint imitation stone coating is directly or indirectly attached to the primer layer (11) as in claim 1. The primer layer (11) is used to attach to a substrate (W). The main material is used to provide a stone-like texture of the low-carbon footprint imitation stone coating. The main material includes an inorganic aggregate, which is a silicide obtained by reprocessing silicon-containing waste. The main material of the low-carbon footprint imitation stone coating as described in claim 15, wherein the inorganic aggregate is spherical silica obtained by reprocessing the silicon-containing waste, with a diameter ranging from 3 to 30 μm. The main material of the low-carbon footprint imitation stone coating as described in claim 16, wherein the D50 particle size of the spherical silica is approximately 20 μm. The main material of the low-carbon footprint imitation stone coating as described in claim 15, wherein the inorganic aggregate is silicon carbide obtained by reprocessing the silicon-containing waste. The main material of the low-carbon footprint imitation stone coating as described in claim 15, wherein the main material comprises a pigment in an amount of approximately 0% to 10% by weight, an inorganic aggregate in an amount of approximately 5% to 65% by weight, and a resin in an amount of approximately 5% to 35% by weight. The main material of the low-carbon footprint imitation stone coating described in claim 15 complies with the requirements of the Green Building Materials Label.