Ultrathin soft porcelain material and production method thereof

Abstract

The invention provides an ultrathin soft porcelain material which comprises a surface layer and a bottom film layer which are tightly combined with each other, the surface layer is made of a soft porcelain material, the bottom film layer is made of a flexible resin material, and the total thickness of the soft porcelain layer and the bottom film layer is 1-1.5 mm. The invention further provides a production method of the ultrathin soft porcelain material. The production method comprises the three steps of material preparation, baking and gluing. The surface layer of the soft porcelain material and the bottom film layer of the flexible resin material are combined into an integrated structure, so that the bottom film layer provides an attaching and supporting surface for the surface layer, the connectivity and stability between the soft porcelain materials in the surface layer are kept, and the conditions of breakage and surface falling caused by structure loosening are avoided. Meanwhile, the flexible resin material can have high structural strength and toughness in a thin state, and after the flexible resin material is combined with the soft porcelain material, the super soft porcelain material is formed, so that the production and transportation cost is lower, the pasting process is more convenient, and the service life is longer.

Description

Technical Field

[0001] The invention relates to the technical field of soft porcelain material production, and in particular to an ultra-thin soft porcelain material and a production method thereof. Background Art

[0002] With the development of modern building decoration technology, people have put forward higher and more comprehensive requirements for decoration effects. On some curved or irregular exterior wall surfaces, it is difficult to completely cover the surface with traditional tiles, so soft porcelain products came into being. Soft porcelain was originally a decorative sheet made of modified clay and baked at low temperature with a decorative effect similar to that of ceramic tiles. Because it has a certain degree of flexibility and can be shaped according to the object, it is named "soft porcelain".

[0003] Up to now, soft porcelain mostly uses stone powder and calcium powder as aggregates, cement and water-based resin (emulsion) as bonding materials, and is formed by low-temperature curve baking. It can fully show the texture of natural marble, wood, and leather, and is used to replace traditional decorative materials such as tiles, real stone paint, and coatings. What distinguishes soft porcelain from traditional tiles is its texture. Soft tiles have a soft texture, prominent patterns, and a strong three-dimensional sense. Soft porcelain has the advantages of flexibility and not easy to break. It is a new type of low-carbon, environmentally friendly, green, lightweight building decoration material. Because of its light weight, good flexibility, diverse shapes, and good weather resistance, it is widely used in more and more fields such as high-rise buildings, interior decoration, large public entertainment venues, and public transportation facilities.

[0004] With the development of soft porcelain, people's requirements for its technical indicators are getting higher and higher, and thickness is one of the important technical indicators of soft porcelain materials. The thinner the soft porcelain is, the lower its production and transportation costs will be, the more convenient the posting process will be, and it will be less likely to fall off or deform during long-term use. However, soft porcelain is limited by its own structural strength problems, resulting in the current thickness mostly between 2-10mm. If it is thinner, it is prone to problems such as breakage and falling off. Sometimes, in order to increase the strength, it is also necessary to implant a reinforcing mesh inside the soft porcelain sheet to further increase the thickness. Therefore, a special soft porcelain structure and process are urgently needed to prepare thinner soft porcelain materials. Summary of the invention

[0005] In view of the deficiencies in the prior art, the present invention provides an ultra-thin soft porcelain material and a production method thereof, which solves the problem that the thickness of the soft porcelain material in the prior art cannot be further reduced due to its structural strength, and further improvements cannot be obtained in production and transportation costs, posting convenience and service life.

[0006] In the first aspect, the present invention proposes an ultra-thin soft ceramic material, comprising a surface layer and a bottom film layer tightly combined with each other, wherein the surface layer is a soft ceramic material, the bottom film layer is a flexible resin material, and the total thickness of the soft ceramic layer and the bottom film layer is 1-1.5 mm.

[0007] Preferably, the surface layer comprises the following components in proportion by weight: 10 to 30 parts of heavy calcium, 50 to 70 parts of quartz sand, and 4 to 15 parts of water-based resin.

[0008] Preferably, the water-based resin is a mixture of one or more of acrylic resin, water-based polyurethane and water-based epoxy resin.

[0009] Furthermore, the bottom film layer is a light-transmitting flexible resin material.

[0010] Preferably, the material of the base film layer includes one of acrylic resin, polyurethane resin and flexible epoxy resin.

[0011] Furthermore, the thickness of the soft porcelain layer is 0.3-0.8 mm, and the thickness of the base film layer is 0.5-1.0 mm.

[0012] In a second aspect, the present invention further provides a method for producing an ultra-thin soft ceramic material, comprising the following steps:

[0013] S1. Material preparation: prepare the raw materials according to the set surface layer component ratio, process the heavy calcium into 400 mesh powder, and screen 80-120 mesh quartz sand powder, then add 10%-30% of the total weight of the raw materials while stirring with a mixer until the raw materials are fully dissolved and gelled, so that the viscosity reaches 2000-2800 Pa·s;

[0014] S2, baking: injecting the raw material prepared in step S1 into a template of a preset size, coating it to a uniform thickness, and then conveying it into a baking chamber via a conveyor belt, baking it at 80° C. for 2 to 6 hours, and taking it out after baking to cool naturally to obtain a hardened and formed surface layer;

[0015] S3, gluing: evenly apply the liquid base film material on the hardened surface layer, and then dry it at a low temperature of 40-60°C for 3-6 hours to harden the base film layer and tightly bond it to the surface layer to obtain an ultra-thin soft porcelain material.

[0016] Furthermore, the method further comprises a coloring step, wherein a color pattern is formed on the outer side of the surface layer through the coloring step.

[0017] Preferably, the base film layer is made of transparent material, and the coloring step is performed by spraying coloring. After the gluing in step S3 is completed, a spray gun or a printing machine is used to spray paint on the outside of the surface layer for coloring.

[0018] Preferably, the coloring step is specifically as follows: in step S3, the color powder is added to the liquid base film layer material and stirred to make it evenly mixed, and then the base film layer material is coated on the surface layer. During the natural hardening process of the base film layer, the color powder penetrates from the base film layer into the surface layer to form a color pattern.

[0019] Compared with the prior art, the present invention has the following beneficial effects:

[0020] The present invention combines the surface layer of the soft porcelain material with the bottom film layer of the flexible resin material. Since the soft porcelain material itself is a loose porous structure to a certain extent, when the flexible resin material is coated on the surface of the soft porcelain material in a thermoplastic state, it will partially penetrate from the contact surface into the inside of the soft porcelain material to form a tight bonding surface, so that the surface layer and the bottom film layer are fully bonded into an integrated structure. Then, the bottom film layer provides an attachment and support surface for the surface layer, instead of relying solely on the internal connection force of the soft porcelain material to provide strength. In this way, when the surface layer is made thinner, it can still rely on the bottom film layer to provide support for it, maintain connectivity and stability, and will not break or fall off due to loose structure. At the same time, the flexible resin material itself can have higher structural strength and toughness in a relatively thin state. After being combined with the soft porcelain material, they form a super soft porcelain material together, which makes its production and transportation costs lower, the posting process more convenient, and the service life longer.

[0021] In addition, since the base film layer of the present invention is a translucent resin material and the surface layer thickness is extremely low, it has a certain degree of translucency. Compared with the traditional completely opaque soft porcelain material, when applied on buildings, it has better light aesthetics and can be designed with more shapes. DETAILED DESCRIPTION

[0022] The technical solution of the present invention is further described below in conjunction with embodiments.

[0023] Embodiment 1:

[0024] An ultra-thin soft ceramic material in this embodiment includes a surface layer and a bottom film layer that are tightly combined with each other, the surface layer is a soft ceramic material, and the bottom film layer is a flexible resin material, wherein the thickness of the soft ceramic layer is 0.3 mm, the thickness of the bottom film layer is 1.0 mm, and the total thickness of the soft ceramic layer and the bottom film layer is 1.3 mm.

[0025] Specifically, the surface layer includes the following components in proportion by weight: 10 parts of heavy calcium, 50 parts of quartz sand, and 4 parts of water-based resin. The water-based resin is acrylic resin.

[0026] The material of the bottom film layer is acrylic resin.

[0027] A method for producing an ultra-thin soft ceramic material in this embodiment includes the following steps:

[0028] Step 1: Prepare the raw materials according to the set surface layer composition ratio, process the heavy calcium into 400 mesh powder, and screen 80 mesh quartz sand powder, then add 10% of the total weight of the raw materials with a mixer while stirring until the raw materials are fully dissolved and gelled, so that the viscosity reaches 2000 Pa·s;

[0029] Step 2, baking: inject the raw material prepared in step 1 into a template of a preset size, apply it to a uniform thickness, and then send it into a baking chamber through a conveyor belt, bake it at 80°C for 2 hours, take it out after baking and let it cool naturally to obtain a hardened and formed surface layer;

[0030] Step 3: Gluing: Add the color powder to the liquid base film material and stir to mix it evenly, then evenly apply it on the hardened surface layer, and dry it at 40°C for 3 hours to harden the base film layer and tightly bond it to the surface layer. At the same time, the color powder penetrates from the base film layer to the surface layer to form a color pattern, thus obtaining an ultra-thin soft porcelain material.

[0031] Embodiment 2:

[0032] An ultra-thin soft ceramic material in this embodiment includes a surface layer and a bottom film layer that are tightly combined with each other, the surface layer is a soft ceramic material, and the bottom film layer is a flexible resin material, wherein the thickness of the soft ceramic layer is 0.8 mm, the thickness of the bottom film layer is 0.5 mm, and the total thickness of the soft ceramic layer and the bottom film layer is 1.3 mm.

[0033] Specifically, the surface layer includes the following components in proportion by weight: 30 parts of heavy calcium, 70 parts of quartz sand, and 15 parts of water-based resin. The water-based resin is a mixture of water-based polyurethane and water-based epoxy resin in equal proportions.

[0034] The material of the bottom film layer is polyurethane resin.

[0035] A method for producing an ultra-thin soft ceramic material in this embodiment includes the following steps:

[0036] Step 1: Prepare the raw materials according to the set surface layer composition ratio, process the heavy calcium into 400 mesh powder, and screen the 120 mesh quartz sand powder, then add 30% of the total weight of the raw materials with water while stirring with a mixer until the raw materials are fully dissolved and gelled, so that the viscosity reaches 2800 Pa·s;

[0037] Step 2, baking: inject the raw material prepared in step 1 into a template of a preset size, apply it to a uniform thickness, and then send it into a baking chamber through a conveyor belt, bake it at 80°C for 6 hours, take it out after baking and let it cool naturally to obtain a hardened and formed surface layer;

[0038] Step 3: Gluing: Add the color powder to the liquid base film material and stir to mix it evenly, then evenly apply it on the hardened surface layer, and dry it at 60°C for 6 hours to harden the base film layer and tightly bond it to the surface layer. At the same time, the color powder penetrates from the base film layer to the surface layer to form a color pattern, thus obtaining an ultra-thin soft porcelain material.

[0039] Embodiment 3:

[0040] An ultra-thin soft ceramic material in this embodiment includes a surface layer and a bottom film layer which are tightly combined with each other, wherein the surface layer is a soft ceramic material, and the bottom film layer is a flexible resin material, wherein the thickness of the soft ceramic layer is 0.4 mm, the thickness of the bottom film layer is 0.6 mm, and the total thickness of the soft ceramic layer and the bottom film layer is 1 mm.

[0041] Specifically, the surface layer includes the following components in proportion by weight: 20 parts of heavy calcium, 60 parts of quartz sand, and 9 parts of water-based resin. The water-based resin is a mixture of acrylic resin, water-based polyurethane, and water-based epoxy resin in equal proportions.

[0042] The material of the bottom film layer is flexible epoxy resin.

[0043] A method for producing an ultra-thin soft ceramic material in this embodiment includes the following steps:

[0044] Step 1: Prepare the raw materials according to the set surface layer composition ratio, process the heavy calcium into 400 mesh powder, and screen the 100 mesh quartz sand powder, then add 20% of the total weight of the raw materials while stirring with a mixer until the raw materials are fully dissolved and gelled, so that the viscosity reaches 2400 Pa·s;

[0045] Step 2, baking: inject the raw material prepared in step 1 into a template of a preset size, apply it to a uniform thickness, and then send it into a baking chamber through a conveyor belt, bake it at 80°C for 4 hours, take it out after baking and let it cool naturally to obtain a hardened and formed surface layer;

[0046] Step 3: Gluing: Add the color powder to the liquid base film material and stir to mix it evenly, then evenly apply it on the hardened surface layer, and dry it at 50°C for 4.5 hours to harden the base film layer and tightly bond it to the surface layer. At the same time, the color powder penetrates from the base film layer to the surface layer to form a color pattern, thus obtaining an ultra-thin soft porcelain material.

[0047] Embodiment 4:

[0048] An ultra-thin soft ceramic material in this embodiment includes a surface layer and a bottom film layer which are tightly combined with each other, wherein the surface layer is a soft ceramic material, and the bottom film layer is a flexible resin material, wherein the thickness of the soft ceramic layer is 0.7 mm, the thickness of the bottom film layer is 0.8 mm, and the total thickness of the soft ceramic layer and the bottom film layer is 1.5 mm.

[0049] Specifically, the surface layer includes the following components in proportion by weight: 18 parts of heavy calcium, 55 parts of quartz sand, and 10 parts of water-based resin. The water-based resin is a mixture of acrylic resin and water-based polyurethane in equal proportions.

[0050] The material of the bottom film layer is polyurethane resin.

[0051] A method for producing an ultra-thin soft ceramic material in this embodiment includes the following steps:

[0052] Step 1: Prepare the raw materials according to the set surface layer composition ratio, process the heavy calcium into 400 mesh powder, and screen the 120 mesh quartz sand powder, then add 10% of the total weight of the raw materials with a mixer while stirring until the raw materials are fully dissolved and gelled, so that the viscosity reaches 2800 Pa·s;

[0053] Step 2, baking: inject the raw material prepared in step 1 into a template of a preset size, apply it to a uniform thickness, and then send it into a baking chamber through a conveyor belt, bake it at 80°C for 6 hours, take it out after baking and let it cool naturally to obtain a hardened and formed surface layer;

[0054] Step 3: Gluing: Then evenly apply it on the hardened surface layer, dry it at 40°C for 6 hours to harden the base film layer and tightly bond it to the surface layer, then use a spray gun or printer to spray paint on the outside of the surface layer to obtain an ultra-thin soft porcelain material.

[0055] Comparative Example 1:

[0056] The ultra-thin soft ceramic material prepared in this comparative example does not have a bottom film layer, and the thickness of its surface layer is 2 mm. The rest is the same as that of Example 2.

[0057] In order to better illustrate the above-mentioned index performance of the soft porcelain of the present invention, the present invention conducted a comparative technical performance test on the soft porcelain products prepared in Examples 1-4. The test results are shown in the following table:

[0058]

[0059]

[0060] Table 1

[0061] It can be seen from Table 1 that, compared with Comparative Example 1, the four embodiments of the present invention have significantly improved flexibility and transmittance indicators while maintaining other key parameters qualified, which fully demonstrates the flexibility and light transmittance of the present invention.

[0062] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of the present invention rather than to limit it. Although the present invention has been described in detail with reference to the preferred embodiments, those skilled in the art should understand that the technical solution of the present invention can be modified or replaced by equivalents without departing from the purpose and scope of the technical solution of the present invention, which should be included in the scope of the claims of the present invention.

Claims

1. An ultra-thin soft ceramic material, characterized in that: It comprises a surface layer and a bottom film layer which are closely combined with each other, the surface layer is made of soft porcelain material, the bottom film layer is made of flexible resin material, and the total thickness of the soft porcelain layer and the bottom film layer is 1-1.5 mm.

2. An ultra-thin soft ceramic material as claimed in claim 1, characterized in that: The surface layer comprises the following components in proportion by weight: 10 to 30 parts of heavy calcium, 50 to 70 parts of quartz sand, and 4 to 15 parts of water-based resin.

3. An ultra-thin soft ceramic material as claimed in claim 2, characterized in that: The water-based resin is a mixture of one or more of acrylic resin, water-based polyurethane and water-based epoxy resin.

4. The ultra-thin soft ceramic material according to claim 1, characterized in that: The bottom film layer is a light-transmitting flexible resin material.

5. The ultra-thin soft ceramic material according to claim 4, characterized in that: The material of the bottom film layer includes one of acrylic resin, polyurethane resin and flexible epoxy resin.

6. The ultra-thin soft ceramic material according to claim 1, characterized in that: The thickness of the soft porcelain layer is 0.3-0.8 mm, and the thickness of the base film layer is 0.5-1.0 mm.

7. A method for producing an ultra-thin soft ceramic material as claimed in claim 1, characterized in that: The steps include: S1. Material preparation: prepare the raw materials according to the set surface layer component ratio, process the heavy calcium into 400 mesh powder, and screen 80-120 mesh quartz sand powder, then add 10%-30% of the total weight of the raw materials while stirring with a mixer until the raw materials are fully dissolved and gelled, so that the viscosity reaches 2000-2800 Pa·s; S2, baking: injecting the raw material prepared in step S1 into a template of a preset size, coating it to a uniform thickness, and then conveying it into a baking chamber via a conveyor belt, baking it at 80° C. for 2 to 6 hours, and taking it out after baking to cool naturally to obtain a hardened and formed surface layer; S3, gluing: evenly apply the liquid base film material on the hardened surface layer, and then dry it at a low temperature of 40-60°C for 3-6 hours to harden the base film layer and tightly bond it to the surface layer to obtain an ultra-thin soft porcelain material.

8. The method for producing an ultra-thin soft porcelain material according to claim 7, characterized in that: The method further comprises a coloring step, wherein a color pattern is formed on the outer side of the surface layer through the coloring step.

9. The method for producing an ultra-thin soft ceramic material according to claim 8, characterized in that: The base film layer is a transparent material, and the coloring step is performed by spraying. After the gluing step S3 is completed, a spray gun or a printing machine is used to spray paint on the outside of the surface layer for coloring.

10. The method for producing an ultra-thin soft ceramic material according to claim 8, characterized in that: The coloring step is specifically as follows: in step S3, color powder is added to the liquid base film layer material and stirred to make it evenly mixed, and then the base film layer material is coated on the surface layer. During the natural hardening process of the base film layer, the color powder penetrates from the base film layer to the surface layer and forms a color pattern.

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