A high-grade simulated marble and its preparation method

Abstract

The present invention relates to the technical field of simulated marble, and specifically discloses a high-grade simulated marble. The simulated marble includes a substrate layer, and a surface layer is provided on the upper part of the substrate layer. The surface layer includes a dry granule glaze layer, an inkjet printing layer, a protective glaze layer, and a suet jade dry granule layer from bottom to top; the inkjet printing layer is formed by an inkjet printer; the dry granule glaze layer is prepared from dry granules: glaze: suspending agent = 15-60%: 40-85%: 100%. The product of the present invention has a three-dimensional pattern, delicate texture, and a high degree of imitation of marble. In addition to the inkjet elements, it creates a crystal-clear texture of stone; it overcomes the water ripples of ordinary ceramic tiles and slabs, the surface is smooth and flat, and the flatness is close to that of a mirror; the product texture runs through the bottom and the surface, can meet various processing methods, and highlights the three-dimensional sense of the texture.

Description

Technical Field

[0001] The invention relates to the technical field of marble, and in particular to high-grade simulated marble and a preparation method thereof. Background Art

[0002] In the field of modern decoration, high-end marble is favored by high-end consumers for its noble texture, rare grain and jade-like touch. However, due to the influence of natural formation conditions, its strength and wear resistance are worse than ceramic tiles. Developing a building decoration product that can achieve the texture and appearance of high-end marble while overcoming the shortcomings of its physical and chemical properties has become an important research and development technology direction in the field of building materials. For imitation marble tiles, it is difficult to achieve the texture effect of high-end marble, the crystal clear texture and the touch as warm as jade. The surface effect is not three-dimensional, and it is purely a pattern composed of different grayscales printed by inkjet. It does not have the delicate texture and texture of stone. The surface has serious water ripples, and the material feels like a plastic board. The pattern texture does not penetrate the body, but is only on the surface. It is not suitable for use in high-end home decoration. The product has a weak sense of thickness and obvious traces of human intervention. After paving, the uneven places between the bricks have a kicking phenomenon, which can generally be re-polished and repaired in stone applications, while ceramic tiles and rock slabs cannot be polished again. Repeated polishing will wear through the protective layer and damage the product pattern. There is a white line produced by cosmetic soil between the glaze layer and the body of ordinary products, which affects the appearance.

[0003] Although the existing simulated marble has wear resistance, it has low smoothness and its performance cannot be improved in a coordinated manner. At the same time, the product performance is prone to deterioration under acid and alkali conditions, resulting in low product efficiency. The product needs further improvement and processing. Summary of the invention

[0004] In view of the defects of the prior art, the object of the present invention is to provide a high-grade simulated marble and a preparation method thereof to solve the problems raised in the above background technology.

[0005] The present invention solves the technical problem by adopting the following technical solution:

[0006] The invention provides a high-grade simulated marble, which comprises a base layer, a surface layer is arranged on the upper part of the base layer, and the surface layers are respectively a dry particle glaze layer, an inkjet printing layer, a protective glaze layer, and a mutton-fat jade dry particle layer from bottom to top; the inkjet printing layer is formed by an inkjet printer; the dry particle glaze layer is prepared by dry particles: glaze: suspending agent = 15-60%: 40-85%: 100%.

[0007] Preferably, the glaze comprises the following raw materials in weight percentage: 5-10% kaolin, 0-10% quartz, 20-50% potassium feldspar, 5-10% sodium feldspar, 10-50% low-temperature frit, 0-5% talc, and 0-5% wollastonite.

[0008] Preferably, the composition of the dry granules comprises the following raw materials in weight percentages: , , .

[0009] Preferably, the suspending agent is sodium carboxymethyl cellulose.

[0010] Preferably, the protective glaze layer comprises the following raw materials in weight percentages: kaolin 5-10%, quartz powder 5-15%, whitening powder 0-15%, low-temperature frit 5-20%, calcined talc 1-9%, wollastonite 0-8%, zinc oxide 1-6%.

[0011] Preferably, the low-temperature frit in the protective glaze layer and the glaze comprises the following raw materials in weight percentages:

[0012] .

[0013] The suet jade dry granule layer comprises the following raw materials in weight percentages:

[0014] Potassium feldspar 20-50%, quartz 0-15%, barium carbonate 1-12%, dolomite 0-22%, calcite 1-26%, boric acid 0-8%, zinc oxide 1-11% and modified aluminum borate whiskers 1-5%.

[0015] Preferably, the preparation method of the modified aluminum borate whiskers is as follows:

[0016] S01: Add aluminum borate whiskers into 3-5 times of hydrochloric acid solution, then add 10-20% of alkyl sulfonate and 1-5% of sodium oxalate based on the weight of the aluminum borate whiskers, and stir evenly;

[0017] S02: Add alumina into 2-3 times of sodium alginate solution, then add 5-10% of chitosan and 1-5% of lanthanum sulfate based on the total amount of alumina, and stir thoroughly to obtain an alumina additive;

[0018] S03: Add the alumina additive into the product of S01 according to a weight ratio of 1:6, stir thoroughly, wash with water and dry to obtain the modified aluminum borate whiskers.

[0019] The inventor of the present invention found that adding modified aluminum borate whiskers to the suet jade dry granule layer and adopting the protective glaze layer can synergistically enhance the performance. At the same time, the modified aluminum borate whiskers prepared by the method of the present invention can improve the corrosion resistance of the product, and the product still has stable gloss and wear resistance in a salt spray environment.

[0020] Preferably, the mass fractions of the hydrochloric acid solution and the sodium alginate solution are 2-6% and 10-20% respectively.

[0021] Preferably, the temperature for sufficient stirring in S03 is 55-65°C.

[0022] The present invention also provides a method for preparing high-grade imitation marble, comprising the following steps: First, dry particle glaze layer is applied on the substrate layer, then an inkjet printing layer is formed by inkjet printing, then a protective glaze layer is sprayed and a suet jade dry particle layer is arranged, and then sintered at 1150-1220°C for 1-2 h, and finally polished to obtain high-grade imitation marble.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] The product pattern of the present invention has a three-dimensional sense, delicate texture, and a high degree of imitation of marble. Except for the inkjet element, the texture of the stone is made crystal clear; it overcomes the water ripples of ordinary tiles and rock slabs, the surface is smooth and flat, and the flatness is close to that of a mirror; the product texture runs through the bottom and the surface, can meet various processing methods, and highlights the three-dimensional sense of the texture; the surface layer is thick. If there are uneven places after the product is laid, it can be repaired and polished again to be as flat as before; the surface of the product can use the stone crystal plating method to effectively protect the surface; the scratches generated during construction can be effectively repaired. Using the zirconium-free semi-transparent special glaze technology, the white body between the glaze layer and the body layer of the product is removed, enhancing the visual effect of the body-glaze integration. Through the raw material ratio in the suet jade dry particle layer and the added modified aluminum borate whiskers, the wear resistance of the product can be enhanced while improving the smoothness of the product, improving the performance advantages of the product. Specific embodiments

[0025] The following combines specific embodiments to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without making creative efforts fall within the protection scope of the present invention.

[0026] A high-grade imitation marble in this embodiment, the imitation marble includes a substrate layer, and a surface layer is provided on the upper part of the substrate layer. The surface layer from bottom to top is respectively a dry particle glaze layer, an inkjet printing layer, a protective glaze layer, and a suet jade dry particle layer; the inkjet printing layer is formed by an inkjet printer; the dry particle glaze layer is prepared from dry particles: glaze: suspending agent = 15-60%: 40-85%: 100%.

[0027] The glaze in this embodiment includes the following raw materials by weight percentage: kaolin 5-10%, quartz 0-10%, potassium feldspar 20-50%, sodium feldspar 5-10%, low-temperature frit 10-50%, talc 0-5%, wollastonite 0-5%.

[0028] The composition of the dry particles in this embodiment includes the following raw materials by weight percentage: , , .

[0029] The suspending agent in this example is sodium carboxymethyl cellulose.

[0030] The protective glaze layer in this example comprises raw materials in the following weight percentages: kaolin 5 - 10%, quartz powder 5 - 15%, whitening powder 0 - 15%, low-temperature frit 5 - 20%, calcined talc 1 - 9%, wollastonite 0 - 8%, zinc oxide 1 - 6%.

[0031] The low-temperature frit in the protective glaze layer and the glaze in this example comprises raw materials in the following weight percentages:

[0032] .

[0033] The suet jade-like dry granule layer comprises raw materials in the following weight percentages:

[0034] Potassium feldspar 20 - 50%, quartz 0 - 15%, barium carbonate 1 - 12%, dolomite 0 - 22%, calcite 1 - 26%, boric acid 0 - 8%, zinc oxide 1 - 11% and modified aluminum borate whisker 1 - 5%.

[0035] The preparation method of the modified aluminum borate whisker in this example is as follows:

[0036] S01: Add aluminum borate whisker into 3 - 5 times of hydrochloric acid solution, then add 10 - 20% of alkyl sulfonate and 1 - 5% of sodium oxalate based on the weight of aluminum borate whisker, and stir evenly;

[0037] S02: Add alumina into 2 - 3 times of sodium alginate solution, then add 5 - 10% of chitosan and 1 - 5% of lanthanum sulfate based on the total amount of alumina, stir thoroughly to obtain an alumina additive;

[0038] S03: Add the alumina additive into the product of S01 according to a weight ratio of 1:6, stir thoroughly, wash with water and dry to obtain the modified aluminum borate whisker.

[0039] The mass fractions of the hydrochloric acid solution and the sodium alginate solution in this example are 2 - 6% and 10 - 20% respectively.

[0040] The temperature for thorough stirring in S03 of this example is 55 - 65 °C.

[0041] The preparation method of a high-grade simulated marble in this example comprises the following steps: First, apply a dry granule glaze layer on the substrate layer, then form an inkjet printing layer by inkjet printing, then spray a protective glaze layer and arrange a suet jade-like dry granule layer, then sinter at 1150 - 1220 °C for 1 - 2 h, and finally perform a polishing treatment to obtain a high-grade simulated marble.

[0042] Example 1.

[0043] A high-grade simulated marble of the present embodiment comprises a base layer, a surface layer is arranged on the upper part of the base layer, and the surface layers are respectively a dry particle glaze layer, an inkjet printing layer, a protective glaze layer, and a mutton-fat jade dry particle layer from bottom to top; the inkjet printing layer is formed by an inkjet printer; the dry particle glaze layer is prepared by dry particles: glaze: suspending agent = 15%: 40%: 100%.

[0044] The glaze of this embodiment includes the following raw materials in weight percentage: 5% kaolin, 2% quartz, 20% potassium feldspar, 5% sodium feldspar, 10% low-temperature frit, 1% talc, and 2% wollastonite.

[0045] The ingredients of the dry granules of this embodiment include the following raw materials in weight percentage: , , .

[0046] The suspending agent of the present embodiment is sodium carboxymethyl cellulose.

[0047] The protective glaze layer of this embodiment includes the following raw materials in weight percentage: 5% kaolin, 5% quartz powder, 2% whitening powder, 5% low-temperature frit, 1% burned talc, 2% wollastonite, and 1% zinc oxide.

[0048] The protective glaze layer and the low-temperature frit in the glaze of this embodiment include the following raw materials in weight percentage:

[0049] .

[0050] The mutton-fat jade dry particle layer comprises the following raw materials in weight percentage:

[0051] Potassium feldspar 20%, quartz 2%, barium carbonate 1%, dolomite 22%, calcite 2%, boric acid 2%, zinc oxide 2% and modified aluminum borate whisker 1%.

[0052] The preparation method of the modified aluminum borate whisker of this embodiment is:

[0053] S01: Add aluminum borate whiskers to 3 times hydrochloric acid solution, then add 10% sodium alkyl sulfonate and 1% sodium oxalate of aluminum borate whiskers and stir evenly;

[0054] S02: adding alumina to a 2-fold sodium alginate solution, then adding 5% chitosan and 1% lanthanum sulfate based on the total amount of alumina, stirring thoroughly to obtain an alumina additive;

[0055] S03: Add the aluminum oxide additive to the S01 product in a weight ratio of 1:6, stir thoroughly, wash with water, and dry to obtain modified aluminum borate whiskers.

[0056] In this embodiment, the mass fractions of the hydrochloric acid solution and the sodium alginate solution are 2% and 10% respectively.

[0057] In this embodiment, the temperature for sufficient stirring in S03 is 55 °C.

[0058] A preparation method of a high-grade simulated marble in this embodiment includes the following steps: First, spray a dry particle glaze layer on the substrate layer, then form an inkjet printing layer by inkjet printing, then spray a protective glaze layer and arrange a suet jade dry particle layer, then sinter at 1150 °C for 1 h, and finally perform polishing treatment to obtain the high-grade simulated marble.

[0059] Example 2.

[0060] A high-grade simulated marble in this embodiment, the simulated marble includes a substrate layer, and a surface layer is provided on the upper part of the substrate layer. The surface layer includes a dry particle glaze layer, an inkjet printing layer, a protective glaze layer, and a suet jade dry particle layer from bottom to top; the inkjet printing layer is formed by an inkjet printer; the dry particle glaze layer is prepared from dry particles: glaze: suspending agent = 60%: 85%: 100%.

[0061] The glaze in this embodiment includes the following raw materials by weight percentage: kaolin 10%, quartz 10%, potassium feldspar 50%, sodium feldspar 10%, low-temperature frit 50%, talc 5%, wollastonite 5%.

[0062] The composition of the dry particles in this embodiment includes the following raw materials by weight percentage: , , .

[0063] The suspending agent in this embodiment is sodium carboxymethyl cellulose.

[0064] The protective glaze layer in this embodiment includes the following raw materials by weight percentage: kaolin 10%, quartz powder 15%, brightening powder 15%, low-temperature frit 20%, calcined talc 9%, wollastonite 8%, zinc oxide 6%.

[0065] The low-temperature frit in the protective glaze layer and the glaze in this embodiment includes the following raw materials by weight percentage:

[0066] .

[0067] The suet jade dry particle layer includes the following raw materials by weight percentage:

[0068] Potassium feldspar 50%, quartz 15%, barium carbonate 12%, dolomite 22%, calcite 26%, boric acid 8%, zinc oxide 11% and modified aluminum borate whiskers 5%.

[0069] The preparation method of the modified aluminum borate whiskers in this embodiment is:

[0070] S01: Add aluminum borate whiskers into hydrochloric acid solution with a five - fold volume, then add sodium alkyl sulfonate accounting for 20% of the aluminum borate whiskers and sodium oxalate accounting for 5%, and stir evenly.

[0071] S02: Add alumina into sodium alginate solution with a three - fold volume, then add chitosan accounting for 10% of the total amount of alumina and lanthanum sulfate accounting for 5%, and stir thoroughly to obtain an alumina additive.

[0072] S03: Add the alumina additive into the product of S01 according to a weight ratio of 1:6, stir thoroughly, wash with water and dry to obtain modified aluminum borate whiskers.

[0073] In this example, the mass fractions of the hydrochloric acid solution and the sodium alginate solution are 6% and 20% respectively.

[0074] In S03 of this example, the temperature for thorough stirring is 65 °C.

[0075] A preparation method of a high - grade simulated marble in this example includes the following steps: First, spray a dry granule glaze layer on the substrate layer, then form an ink - jet printing layer by ink - jet printing, then spray a protective glaze layer and arrange a suet - like jade dry granule layer, then sinter at 1220 °C for 2 h, and finally perform polishing treatment to obtain a high - grade simulated marble.

[0076] Example 3.

[0077] A high - grade simulated marble in this example, the simulated marble includes a substrate layer, and a surface layer is provided on the upper part of the substrate layer. The surface layer from bottom to top is respectively a dry granule glaze layer, an ink - jet printing layer, a protective glaze layer, and a suet - like jade dry granule layer; the ink - jet printing layer is formed by an ink - jet printer; the dry granule glaze layer is prepared from dry granules: glaze: suspending agent = 35%: 45%: 100%.

[0078] The glaze in this example includes the following raw materials by weight percentage: kaolin 7.5%, quartz 5%, potassium feldspar 35%, sodium feldspar 7.5%, low - temperature frit 30%, talc 3%, wollastonite 3%.

[0079] The composition of the dry granules in this example includes the following raw materials by weight percentage: , , .

[0080] The suspending agent in this example is sodium carboxymethyl cellulose.

[0081] The protective glaze layer in this example includes the following raw materials by weight percentage: kaolin 7.5%, quartz powder 8%, whitening powder 5%, low - temperature frit 10%, calcined talc 4%, wollastonite 4%, zinc oxide 3%.

[0082] The low - temperature frit in the protective glaze layer and the glaze in this example includes the following raw materials by weight percentage:

[0083] .

[0084] The mutton-fat jade dry particle layer comprises the following raw materials in weight percentage:

[0085] Potassium feldspar 35%, quartz 12%, barium carbonate 6%, dolomite 10%, calcite 13%, boric acid 4%, zinc oxide 5%, and modified aluminum borate whisker 3%.

[0086] The preparation method of the modified aluminum borate whisker of this embodiment is:

[0087] S01: Add aluminum borate whiskers to 4 times hydrochloric acid solution, then add 15% sodium alkyl sulfonate and 3% sodium oxalate of aluminum borate whiskers and stir evenly;

[0088] S02: adding alumina to 2.5 times of sodium alginate solution, then adding chitosan (7.5% of the total amount of alumina) and 3% of lanthanum sulfate, stirring thoroughly to obtain an alumina additive;

[0089] S03: Add the aluminum oxide additive to the S01 product in a weight ratio of 1:6, stir thoroughly, wash with water, and dry to obtain modified aluminum borate whiskers.

[0090] The mass fractions of the hydrochloric acid solution and the sodium alginate solution in this embodiment are 4% and 15% respectively.

[0091] The temperature for sufficient stirring in S03 of this embodiment is 60°C.

[0092] The preparation method of a high-grade simulated marble of the present embodiment comprises the following steps: firstly spraying a dry granular glaze layer on a base layer, then inkjet printing to form an inkjet printing layer, then spraying a protective glaze layer, arranging a mutton-fat jade dry granular layer, then sintering at 1175° C. for 1.5 hours, and finally polishing to obtain high-grade simulated marble.

[0093] Comparative Example 1.

[0094] The difference from Example 3 is that no protective glaze layer is used.

[0095] Comparative Example 2.

[0096] The difference from Example 3 is that no modified aluminum borate whiskers are added to the mutton-fat jade dry particle layer.

[0097] Comparative Example 3.

[0098] The difference from Example 3 is that the modified aluminum borate whisker is replaced by aluminum borate whisker.

[0099] Comparative Example 4.

[0100] Different from Example 3, aluminum oxide additive was not added in the preparation of modified aluminum borate whiskers.

[0101] Comparative Example 5.

[0102] Different from Example 3, lanthanum sulfate was not added in the preparation of aluminum oxide additive.

[0103] Comparative Example 6.

[0104] Different from Example 3, sodium alkyl sulfonate was not added in the preparation of modified aluminum borate whiskers.

[0105] The performance measurement results of Examples 1 - 3 and Comparative Examples 1 - 6 are as follows. The wear resistance grade was tested at 2100 revolutions, and the wear loss was tested at 6000 revolutions. The test results are shown in the table;

[0106]

[0107] It can be concluded from Examples 1 - 3 and Comparative Examples 1 - 6 that

[0108] The products of Example 3 have excellent gloss and wear resistance. At the same time, by adding modified aluminum borate whiskers, the wear resistance of the products can be significantly enhanced. Also, when the modified aluminum borate whiskers are replaced with aluminum borate whiskers, aluminum oxide additive is not added in the preparation, lanthanum sulfate is not added in the preparation of aluminum oxide additive, and the preparation methods of the modified aluminum borate whiskers are different, the performance effects of the products are different. The effects of the aluminum borate whiskers prepared by the method of the present invention are the most significant.

[0109] Examples 1 - 3 and Comparative Examples 1 - 6 were placed in a 2% salt spray environment for 1 month, and then the wear loss and gloss performance were tested again;

[0110]

[0111] It can be seen from Examples 1 - 3 and Comparative Examples 1 - 6 that adding modified aluminum borate whiskers and using a protective glaze layer in the suet jade - like dry granule layer, and at the same time using the modified aluminum borate whiskers prepared by the method of the present invention can improve the corrosion resistance of the products, and the products still have stable gloss and wear resistance in the salt spray environment.

[0112] For those skilled in the art, it is obvious that the present invention is not limited to the details of the above - mentioned exemplary embodiments, and without departing from the spirit or basic characteristics of the present invention, the present invention can be implemented in other specific forms. Therefore, in any regard, the embodiments should be regarded as exemplary and non - restrictive. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, it is intended to embrace all changes within the meaning and scope of the equivalent elements of the claims in the present invention.

[0113] In addition, it should be understood that although this specification is described according to embodiments, not every embodiment only contains an independent technical solution. This narrative way of the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A high-grade simulated marble, the simulated marble comprising a matrix layer, Characterized in that, A surface layer is provided on the upper part of the matrix layer, and the surface layer is successively a dry granule glaze layer, an inkjet printing layer, a protective glaze layer, and a suet jade dry granule layer from bottom to top; the inkjet printing layer is formed by an inkjet printer; the dry granule glaze layer is prepared from dry granules: glaze: suspending agent = 15-60%: 40-85%: 100%; The protective glaze layer comprises the following raw materials in weight percentages: kaolin 5-10%, quartz powder 5-15%, whitening powder 0-15%, low-temperature frit 5-20%, calcined talc 1-9%, wollastonite 0-8%, zinc oxide 1-6%; The low-temperature frit in the protective glaze layer and the glaze comprises the following raw materials in weight percentages: SiO 2 53 to 58%, Al 2 O 3 2 to 8%, Na 2 O 1 to 3%, BaO 1 to 5%, ZnO 2 to 7%; The suet jade dry granule layer comprises the following raw materials in weight percentages: Potassium feldspar 20-50%, quartz 0-15%, barium carbonate 1-12%, dolomite 0-22%, calcite 1-26%, boric acid 0-8%, zinc oxide 1-11%, and modified aluminum borate whiskers 1-5%; The preparation method of the modified aluminum borate whiskers is: S01: Add aluminum borate whiskers to 3-5 times the hydrochloric acid solution, then add 10-20% of sodium alkyl sulfonate and 1-5% of sodium oxalate based on the aluminum borate whiskers, and stir evenly; S02: Add alumina to 2-3 times the sodium alginate solution, then add 5-10% of chitosan and 1-5% of lanthanum sulfate based on the total amount of alumina, and stir thoroughly to obtain an alumina additive; S03: Add the alumina additive to the product of S01 in a weight ratio of 1:6, stir thoroughly, wash with water and dry to obtain modified aluminum borate whiskers.

2. A high-grade simulated marble according to claim 1, Characterized in that, The glaze comprises the following raw materials in weight percentages: kaolin 5-10%, quartz 0-10%, potassium feldspar 20-50%, sodium feldspar 5-10%, low-temperature frit 10-50%, talc 0-5%, wollastonite 0-5%.

3. A high-grade simulated marble according to claim 1, Characterized in that, The composition of the dry granules includes raw materials in the following weight percentages: SiO 2 50 - 62%, Al 2 O 3 3 - 19%, K 2 O 0 - 6%, Na 2 O 1 - 6%, CaO 3 5 - 20%, MgO 0 - 5%, BaO 0 - 2%, B 2 O 3 0 - 4%, ZnO 0 - 10%, SrO 0 - 6%.

4. A high-grade simulated marble according to claim 1, Characterized in that, The suspending agent is sodium carboxymethyl cellulose.

5. A high-grade simulated marble according to claim 1, Characterized in that, The mass fractions of the hydrochloric acid solution and the sodium alginate solution are 2-6% and 10-20% respectively.

6. A high-grade simulated marble according to claim 1, Characterized in that, The temperature for thorough stirring in S03 is 55-65 °C.

7. A preparation method of a high-grade simulated marble according to any one of claims 1-6, Characterized in that, Comprises the following steps: First apply the dry granule glaze layer on the matrix layer, then form the inkjet printing layer by inkjet printing, then spray the protective glaze layer and arrange the suet jade dry granule layer, then sinter at 1150-1220 °C for 1-2 h, and finally polish to obtain a high-grade simulated marble.

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