Roll-formed ceramic plate preparation method and ceramic plate

Abstract

The invention provides a roll-formed ceramic plate preparation method and a ceramic plate, and the method comprises the steps: preparing a single-sided adhesive film according to a back grain pattern, the single-sided adhesive film comprises a single-sided adhesive base film and a three-dimensional embossment located on one side of the single-sided adhesive base film; the single-sided adhesive film is laid on a roller press, and the three-dimensional embossment is placed upwards; a fabric layer is arranged on the face, with the three-dimensional embossment, of the single-sided adhesive film through a distributing device of a roller press, rolling is conducted, and a ceramic plate blank with the single-sided adhesive base film attached to the bottom and the three-dimensional embossment embedded into the ceramic plate blank is obtained; the ceramic plate blank is dried, glazed and decorated and then fired, in the drying or firing process, the single-sided adhesive film is ablated, the back pattern is formed at the bottom of the fabric layer, and the ceramic plate with the back pattern is obtained. The back grains can be arranged at will, the demolding process is reduced, and the production efficiency is improved; in the paving process, the ceramic tile can be fully combined with cement mortar and is not prone to falling off, and the paving stability of the ceramic tile is improved.

Description

Technical Field

[0001] The present invention relates to the technical field of ceramic production, and particularly to a method for preparing a ceramic plate by roll forming and a ceramic plate. Background Art

[0002] The firmness of tile laying is related to people's livelihood safety. Due to large climate temperature differences or long-term exposure to wind, sun, rain, and the inconsistent deformation rates of tiles and bonding materials, tile panels are prone to detachment, resulting in the falling off of tile panels and highly likely leading to safety accidents. By changing the structure of the tile back pattern, the bonding strength between the tile and the bonded wall can be increased.

[0003] Most of the current tile back patterns are formed by mold pressing. The depth of the ribs of the pressed back pattern is generally between 0.6 - 0.8 mm. However, due to the limitations of the pressing process when using a mold, the patterns of the back pattern are restricted. Complex patterns will increase the demolding resistance, resulting in tile breakage or mold wear. For example, anti-slip structures such as dovetail grooves can enhance the bonding force, but the angle and depth need to be precisely controlled, otherwise it is easy to get stuck. Therefore, when using a mold to press, the patterns of the back pattern cannot be set arbitrarily. Thus, it is difficult to increase the bonding strength of laying by changing the shape of the back pattern. Moreover, in ceramic production, the mold needs to be opened and closed quickly, and complex patterns will prolong the demolding time and reduce production efficiency.

[0004] Therefore, there are defects in the prior art and it needs to be improved and developed. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a method for preparing a ceramic plate by roll forming and a ceramic plate, aiming at the above-mentioned defects of the prior art, to solve the problems that when using a mold to press, the patterns of the back pattern cannot be set arbitrarily, and complex patterns will prolong the demolding time and reduce production efficiency.

[0006] The technical solution adopted by the present invention to solve the technical problem is as follows:

[0007] A method for preparing a ceramic plate by roll forming, which is realized based on a roll press. Among them, the method includes:

[0008] Prepare a single-sided adhesive film according to a preset back pattern. The single-sided adhesive film includes: a single-sided adhesive base film and a three-dimensional relief on one side of the single-sided adhesive base film, and the three-dimensional relief is made based on the back pattern;

[0009] Lay the single-sided adhesive film on the roll press, and place the three-dimensional relief facing upwards;

[0010] Use the feeder of the roll press to lay a fabric layer on the side of the single-sided adhesive film with a three-dimensional relief, and then perform rolling to obtain a ceramic slab blank with a single-sided adhesive base film adhered to the bottom and a three-dimensional relief embedded inside.

[0011] After the ceramic slab blank is dried, glazed, and decorated, it is fired. During the drying or firing process, the single-sided adhesive film is ablated to form the back pattern at the bottom of the fabric layer, and a ceramic plate with the back pattern is obtained.

[0012] According to the above technical means, the embodiment of the present application does not require the use of a mold, does not require demolding, does not require precise control of the angle and depth, the back pattern can be set arbitrarily, the demolding process is reduced, and the production efficiency is improved; moreover, by using the ablation principle, a back pattern with an increased bonding area can be obtained, so that it can be fully combined with cement mortar during the paving process, is not easy to fall off, and the stability of the ceramic tile paving is improved.

[0013] In an embodiment of the present application, the materials of the single-sided adhesive base film and the three-dimensional relief are both EPE.

[0014] According to the above technical means, the embodiment of the present application prepares the single-sided adhesive film by using EPE material. Compared with the concave-convex mold forming of the ceramic tile back pattern, since the pressing surface of the present application is flat, the flexural strength of the brick body will not be reduced due to the density difference of the concave-convex parts; moreover, the EPE material has a low cost, does not require the use of a mold, does not require demolding, does not require precise control of the angle and depth, and the back pattern can be set arbitrarily. In this way, after the EPE material is ablated, a back pattern with an increased bonding area can be obtained, so that it can be fully combined with cement mortar during the paving process, is not easy to fall off, and the stability of the ceramic tile paving is improved.

[0015] In an embodiment of the present application, the material of the single-sided adhesive base film is a paper material, and the three-dimensional relief is formed by curing the ink printed on the single-sided adhesive base film by a UV printer.

[0016] According to the above technical means, the embodiment of the present application prepares the single-sided adhesive film by using paper materials and UV printing technology, with a low cost, does not require the use of a mold, and the back pattern can be set arbitrarily. In this way, the paper material and the cured ink of UV printing can obtain a back pattern with an increased bonding area after ablation, so that it can be fully combined with cement mortar during the paving process, is not easy to fall off, and the stability of the ceramic tile paving is improved.

[0017] In an embodiment of the present application, the material of the single-sided adhesive base film is a paper material or a mesh yarn, and the material of the three-dimensional relief is paperboard particles.

[0018] According to the above technical means, in the embodiment of the present application, a single-sided adhesive film is prepared by using paper materials or mesh yarns, and paperboard particles. The cost is low, and there is no need to use a mold. The back pattern can be set arbitrarily. In this way, the paper materials, mesh yarns, and paperboard particles can obtain a back pattern with an increased sticking area after ablation, so that it can be fully combined with cement mortar during the paving process and is not easy to fall off, improving the stability of the ceramic tile paving.

[0019] In an embodiment of the present application, a film pulling-out device is provided at the front end of the feeder of the roll press; laying the single-sided adhesive film on the roll press, and placing the three-dimensional relief facing up, including:

[0020] Using the film pulling-out device to flatten the single-sided adhesive film on the steel belt of the roll press, and placing the three-dimensional relief facing up.

[0021] According to the above technical means, in the embodiment of the present application, a film pulling-out device is provided at the front end of the feeder of the roll press, so as to use the film pulling-out device to lay the single-sided adhesive film on the roll press, realizing the automation of the laying of the single-sided adhesive film and reducing the demolding process, thereby improving the production efficiency.

[0022] In an embodiment of the present application, the high-temperature residual carbon content of the single-sided adhesive film at 600 °C is less than 0.55%.

[0023] According to the above technical means, in the embodiment of the present application, by controlling the high-temperature residual carbon content of the single-sided adhesive film at 600 °C to be less than 0.55%, the single-sided adhesive film is completely burned during firing, so as not to cause other defects on the glaze surface.

[0024] In an embodiment of the present application, the thickness of the single-sided adhesive film is 0.2 - 0.8 mm.

[0025] According to the above technical means, compared with the concave-convex mold forming of the ceramic tile back pattern in the embodiment of the present application, since the pressing surface is flat in the present application, the requirement for the height ratio between the fabric layer and the single-sided adhesive film is lower, and the flexural strength of the brick body will not be reduced due to the density difference at the concave-convex parts. Therefore, the thickness of the single-sided adhesive film in the present application can be between 0.2 - 0.8 mm to reduce the production difficulty.

[0026] In an embodiment of the present application, the firing temperature of the ceramic slab body is 1150 - 1220 °C, and the firing time is 45 - 85 minutes.

[0027] According to the above technical means, in the embodiments of the present application, at a temperature of 1150 - 1220 °C, sufficient solid-phase reaction and liquid-phase sintering occur between the ceramic particles, the particles are more closely bonded, the crystal phase structure in the ceramic is more stable, and it is not easy to react with chemical substances such as acids and alkalis, improving the ability to resist chemical erosion; the firing time of 45 - 85 minutes not only ensures the firing effect, but also improves production efficiency and reduces production costs.

[0028] In an embodiment of the present application, the water content of the production powder used for the fabric layer is 8 - 10%.

[0029] According to the above technical means, in the embodiments of the present application, the powder with a water content of 8 - 10% is in the plastic-semi-dry critical state, which can not only maintain the adhesion between the powder particles, but also avoid the loss of control of fluidity caused by excessive water.

[0030] The present application also provides a ceramic board, wherein the ceramic board is prepared by the method for preparing a roll-pressed ceramic board as described above.

[0031] The present application achieves the following effects:

[0032] First, the embodiments of the present application improve the problem that ceramic rock boards and ceramic large boards are prone to falling off during the wall tiling process, enabling them to be fully combined with cement mortar during tiling and improving the safety of ceramic tile tiling.

[0033] Second, the three-dimensional relief materials in the embodiments of the present application generally exist in a solid form at temperatures below 60 °C, with a melting point or ignition point of 130 °C. After exceeding 300 °C, most of them can volatilize or burn, and the residual carbon part can also be completely burned at about 600 °C during the subsequent firing, with a very low residual carbon content, thus not causing other defects on the glaze surface. Gases are generated and pores are left during the drying or firing process of the ceramic tile.

[0034] Third, the single-sided adhesive film in the embodiments of the present application has a certain ductility and stiffness, does not affect the strength of the green body, has a low cost, and is easy to promote. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 is a flowchart of a preferred embodiment of the method for preparing a roll-pressed ceramic board in the present invention.

[0036] Figure 2 is a cross-sectional view of a single-sided adhesive film with a barb groove effect in the present invention.

[0037] Figure 3 is a top view of a first embodiment of a single-sided adhesive film with a barb groove effect in the present invention.

[0038] Figure 4It is a top view of the second embodiment of the single-sided adhesive film with a barb groove effect in the present invention.

[0039] Figure 5 It is a schematic structural view of a ceramic green body before firing in the present invention.

[0040] Figure 6 It is a cross-sectional view of the back pattern effect of the ceramic plate after firing the first and second embodiments of the single-sided adhesive film in the present invention.

[0041] Figure 7 It is a cross-sectional view of the back pattern effect of the ceramic plate after firing another single-sided adhesive film in the present invention.

[0042] Figure 8 It is a top view of the third embodiment of the single-sided adhesive film with a barb groove effect in the present invention.

[0043] Figure 9 It is a cross-sectional view of the third embodiment of the single-sided adhesive film in the present invention. Detailed Embodiments

[0044] To make the objectives, technical solutions and advantages of the present invention clearer and more explicit, the following further elaborates on the present invention by way of examples with reference to the accompanying drawings. It should be understood that the specific examples described herein are only used to explain the present invention and are not used to limit the present invention.

[0045] In recent years, the production and demand of ceramic rock slabs / large slabs have both shown a trend of steady growth and continuous expansion of applications, and the development of ceramic machinery equipment has gradually tended towards large slab and flexibility. Currently, there are mainly three forming methods for rock slabs / large slabs: dry pressing traditional forming, moldless belt forming, and roll pressing forming. Specifically, in the dry pressing traditional forming method, the powder material is loaded into a metal mold and compressed under the action of force. Part of the gas in the voids of the green body is discharged, the particles are displaced and gradually approach each other, and tightly bite each other, finally forming a green body with the same cross-section as the mold cross-section and the shapes of the upper and lower surfaces determined by the upper and lower punches of the mold. The moldless belt forming method is to evenly distribute the powder material on the surface of the conveyor belt according to a predetermined size. After the cloth laying is completed, it is then transported by the conveyor belt to the pressure device for pressing and forming. The cloth laying system of the roll pressing forming method arranges ceramic powder on two very hard motor-driven traction steel belts. The steel belt rotates to send the ceramic powder with a consistent thickness into a pair of opposing pressing rolls for roll pressing and forming. It can produce brick blanks with a width of 1600 mm and an unlimited length. Roll pressing forming has characteristics such as low power consumption, low noise, low pollution, high efficiency, and highly flexible production, and has advantages unparalleled by traditional presses in terms of manufacturing, transportation, installation, etc.

[0046] For plates in the case of extra-large specifications and more thicknesses, the belt forming method without a mold and the roll forming method are generally used and have an absolute quality advantage. However, since ceramic tiles are generally laid with tile adhesive, most of the back surfaces of the slab / large slab products produced by this equipment process are flat without back patterns. If the imported belts or steel belts with back patterns are frequently replaced, the cost will be relatively high. Using traditional roll forming, compared with the belt technology route without a mold, the cost of the steel belt for three-dimensional engraving of back patterns is relatively high. To relieve the cost pressure, manufacturers have successively tried to develop different technical routes for mold back patterns.

[0047] At present, the main technical routes for back pattern preparation are as follows: sticking glue on the steel belt, engraving on the green body, and forming back patterns after the pore-forming agent is fired.

[0048] However, the existing pore-forming agents are selected from at least one of polystyrene, modified starch, polymethyl methacrylate, polyethylene, polycarbonate, polybutene, and polyisoprene, and have the following defects:

[0049] First, the carbon residue of this type of pore-forming agent is too high, and it cannot be completely volatilized as soon as possible after high-temperature firing, which is likely to cause a large number of glaze defects and is only limited to personalized travertine-like products.

[0050] Second, the pore-forming agent in the above pore-forming agent process has no bonding property itself, its bulk density is very low, and it is not easy to combine with the powder material, resulting in easy drifting, delamination, and chromatography in the digital cloth distributor, and thus the positioning fails to reach the expected design pattern position.

[0051] Before the cloth laying in the present invention, a single-sided adhesive film with a special three-dimensional relief pattern effect slightly wider than the width of the stamping powder is continuously pre-laid on the steel belt of the roll press. After the film is laid, a fabric layer is arranged on the film with a cloth distributor, and then it enters continuous roll pressing in the roll press, so that the single-sided adhesive film is closely attached to the production powder material, and then the single-sided adhesive film is seamlessly embedded in the ceramic large slab / rock slab green body, obtaining a ceramic rock slab / large slab green body with better toughness and strength, and the green body strength of the green body can be improved synchronously.

[0052] As Figure 1 shown, the embodiment of the present application provides a method for preparing a roll-formed ceramic plate, and the method for preparing the roll-formed ceramic plate includes:

[0053] Step S100, preparing a single-sided adhesive film according to a preset back pattern, where the single-sided adhesive film includes: a single-sided adhesive base film and a three-dimensional relief on one side of the single-sided adhesive base film, and the three-dimensional relief is made based on the back pattern;

[0054] Step S200, laying the single-sided adhesive film on the roll press, and placing the three-dimensional relief upward;

[0055] Step S300: Use the feeder of the roll press to lay a fabric layer on the side of the single-sided adhesive film with a three-dimensional relief, and perform rolling to obtain a ceramic plate blank with a single-sided adhesive base film adhered to the bottom and a three-dimensional relief embedded inside;

[0056] Step S400: After the ceramic plate blank is dried, glazed, and decorated, it is fired. During the drying or firing process, the single-sided adhesive film is ablated to form the back pattern at the bottom of the fabric layer, obtaining a ceramic plate with the back pattern.

[0057] After the ceramic plate blank of the embodiment of the present application is dried and fired, irregular isolated holes, through holes, or groove structures are formed, which can be used as the back pattern of the ceramic plate. Compared with the back pattern structure formed by die molding, in the embodiment of the present application, through a processing method combining fabric laying and hole forming, the pattern of the back pattern is more flexible and diverse. Compared with the flat surface formed by die molding, the back pattern of the present application has irregularity.

[0058] Specifically, compared with the flat back pattern surface obtained by die molding or other methods such as sticking glue on a steel belt, the back pattern lines of the embodiment of the present application can be set arbitrarily. While making full use of the roll forming principle of the roll press, the single-sided adhesive film with a three-dimensional relief pattern effect is pressed on the bottom pattern surface of the ceramic plate. Since these materials are basically completely ablated after drying or firing, by precisely designing and prefabricating the three-dimensional relief of the corresponding materials, a back pattern with a predetermined pattern effect can be obtained. The method process flow of the embodiment of the present application is simple. Laying the customized single-sided adhesive film is relatively simple and easy to implement. Since there is no need for demolding, there is no need to precisely control the angle and depth, and the back pattern lines can be set arbitrarily; moreover, in ceramic production, there is no longer a need for rapid opening and closing of the mold, so the demolding time is completely saved and the production efficiency is improved. The single-sided adhesive film of the embodiment of the present application has a low cost. Using the ablation principle, it can achieve the barb or local dovetail groove effect that is more beneficial to the paving of cement mortar or tile adhesive, which is difficult to obtain by traditional die processes, greatly enhancing the operability of later paving.

[0059] Therefore, the embodiment of the present application does not need to use a mold, does not need demolding, does not need to precisely control the angle and depth, the back pattern lines can be set arbitrarily, the demolding process is reduced, and the production efficiency is improved; moreover, using the ablation principle can obtain a back pattern with an increased bonding area, so that it can be fully combined with cement mortar during the paving process and is not easy to fall off, improving the stability of the paving of ceramic tiles.

[0060] In the selection of the single-sided adhesive film, low-cost materials are selected, and the single-sided adhesive film is made to have the physical and chemical index and appearance structure characteristic index necessary for this technical process, compatible with the production operability of the customized manufacturer. At the same time, the best residual carbon content technical index and effect are obtained after ablation at 600 °C. Such as Figure 2As shown in the figure, the single-sided adhesive film includes a single-sided adhesive base film 101 and a three-dimensional relief 102 located on one side of the single-sided adhesive base film. The structure of the single-sided adhesive film can be Figure 3 , Figure 4 or other forms. As Figure 5 shown, after laying the fabric layer 103 on the single-sided adhesive film and then roll-forming, after the single-sided adhesive base film 101 and the three-dimensional relief 102 are ablated, a dovetail groove barb structure is formed, as Figure 6 shown.

[0061] In the first specific embodiment of the present application, the materials of the single-sided adhesive base film and the three-dimensional relief are both EPE.

[0062] Specifically, the selected EPE material has a melting point of 50 - 60 °C and a flash point of 100 °C. It is composed of countless independent bubbles generated by physical foaming of low-density polyethylene resin. The structure of the prepared EPE material is non-crosslinked closed-cell. Using this material for corresponding tests, determining the corresponding three-dimensional effects and requirements, and setting the size, and then custom-producing the roll film by a professional manufacturer. The custom production of EPE is simple and easy to implement, and the cost is low. The EPE can be integrally formed, or can be prepared separately and then combined. When combining, single-sided adhesive can be used for pasting.

[0063] During use, install the corresponding roll film laying equipment and layout on the roll-forming equipment. Using the ablation principle, various groove effects that are difficult to obtain by traditional mold processes and are more beneficial to the paving of cement mortar or tile adhesive can be obtained, greatly enhancing the operability of the later paving.

[0064] In the embodiment of the present application, by using EPE material to prepare the single-sided adhesive film, compared with the concave-convex mold forming of the back pattern of ceramic tiles, since the pressing surface in the present application is flat, the flexural strength of the brick body will not be reduced due to the density difference at the concave-convex parts; and the EPE material has a low cost, does not require the use of a mold, does not require demolding, does not require precise control of the angle and depth, and the back pattern can be set arbitrarily. In this way, after the EPE material is ablated, a back pattern with an increased bonding area can be obtained, so that it can be fully combined with the cement mortar during the paving process, is not easy to fall off, and improves the stability of the paving of ceramic tiles.

[0065] In the second specific embodiment of the present application, the material of the single-sided adhesive base film is a paper material, and the three-dimensional relief is formed by curing the ink printed on the single-sided adhesive base film by a UV printer.

[0066] Specifically, the paper material can be a flammable paper material such as straw paper, which has a low cost. In the embodiment of the present application, a UV printer can be added on-site at the front stage of the roll forming and all-digital station to print a three-dimensional relief pattern on the surface of the paper material. The design focuses on cost factors and operability to manufacture an anti-shedding structure, and determines the corresponding three-dimensional effect, thickness, pattern requirements, and size. The thickness is approximately 0.2 - 0.8 mm. Install the corresponding film laying equipment on the rolling equipment and layout it, and then apply the fabric after light curing molding. A UV printer is a digital inkjet printing device that uses UV (ultraviolet) curing technology. Through the ultraviolet rays emitted by a UV LED lamp or a mercury lamp, the photoinitiator in the ink is instantaneously cured to form a firm graphic layer, and the UV ink is sprayed onto the material surface with a piezoelectric nozzle with a micron-level precision.

[0067] In the embodiment of the present application, a single-sided adhesive film is prepared by using a paper material and UV printing technology, which has a low cost, does not require the use of a mold, and the back pattern can be set arbitrarily. In this way, the paper material and the cured ink of UV printing can obtain a back pattern that increases the bonding area after ablation, and then it can be fully combined with the cement mortar during the paving process, is not easy to fall off, and improves the stability of the ceramic tile paving.

[0068] In the third specific embodiment of the present application, the material of the single-sided adhesive base film is a paper material or a mesh yarn, and the material of the three-dimensional relief is paperboard particles.

[0069] Specifically, the embodiment of the present application selects a flammable paper material or a flammable mesh yarn as the single-sided adhesive base film; and then selects a flammable paper material to make paperboard particles with a specific shape and thickness of a single three-dimensional relief structure. The thickness of the paperboard is approximately 0.2 - 0.8 mm. The design of the three-dimensional relief pattern focuses on cost factors and operability to manufacture an anti-shedding structure. Paperboard particles refer to granular materials obtained by recycling and processing waste cardboard or paper, which is a product in the field of renewable resources. Its essence is to process waste paper products into a granular form through processes such as crushing, cleaning, and compressing for further utilization.

[0070] The three-dimensional relief pattern has a structure with a narrowed bottom. A typical three-dimensional relief pattern has a trapezoidal cross-section in part, such as Figure 6 shown; or a partial semi-circle, that is, a shape between a semi-circle and a full circle, such as Figure 7 shown; it can also be a trapezoidal arc edge. The above structures can all obtain the effect of a dovetail groove trapezoid or a barb structure after firing. The three-dimensional relief structure can also be other irregular structures, such as Figure 8 and Figure 9 shown, and it is required that the area projection of the side away from the single-sided adhesive base film (the upper surface, that is, the solid line area in Figure 8 can completely cover the side that fits the single-sided adhesive base film (the lower surface, that is,Figure 8 The area projection of the dashed area) has a characteristic that the reduction value of the lower surface area compared to the upper surface area ranges from 0 to 15%. As Figure 8 shown, both the side away from the single-sided adhesive base film and the side attached to the single-sided adhesive base film can be irregular shapes, such as Figure 9 shown, the side surface of the three-dimensional relief structure can also be an irregular shape. In the embodiment of the present application, a predetermined three-dimensional effect and requirements, as well as size, are determined, and the three-dimensional relief is batch-produced through specific mechanical equipment. That is to say, the paperboard particles are pre-designed and customized for batch production. Through specific equipment, the three-dimensional relief pattern is laid on the single-sided adhesive base film at the required positions and quantities by a double-sided lamination device to form a single-sided adhesive film with a three-dimensional relief structure. Then, a corresponding laying structure is designed and installed at the front section of the rolling press, so that the single-sided adhesive film is laid on the steel belt for subsequent fabric laying, or is pre-processed and laid into a rolled film, and then unfolded and pasted on the steel belt running on the roll forming machine.

[0071] In the embodiment of the present application, the single-sided adhesive film is prepared by using paper materials or mesh yarns, as well as paperboard particles, with low cost and without using molds. The back patterns can be set arbitrarily. In this way, the paper materials, mesh yarns, and paperboard particles can obtain back patterns with an increased pasting area after ablation, and thus can be fully combined with the cement mortar during the pasting process, are not easy to fall off, and improve the stability of the ceramic tile pasting.

[0072] In an embodiment of the present application, a film drawing-out device is provided at the front end of the cloth distributor of the rolling press; when laying the single-sided adhesive film on the rolling press with the three-dimensional relief facing upwards, it includes:

[0073] Using the film drawing-out device to flatten the single-sided adhesive film on the steel belt of the rolling press with the three-dimensional relief facing upwards.

[0074] Specifically, the ceramic plate in the embodiment of the present application adopts a roll forming method during pressing and forming. During cloth laying, a single-sided adhesive film with a three-dimensional relief pattern effect that is slightly wider than the width of the stamping powder is continuously pre-laid flat on the steel belt of the rolling press. After laying the film, a fabric layer is then laid on the film by a cloth distributor, and then continuous rolling is carried out.

[0075] In the embodiment of the present application, a film drawing-out device is provided at the front end of the cloth distributor of the rolling press, so that the single-sided adhesive film is laid on the rolling press by using the film drawing-out device, realizing the automation of the single-sided adhesive film laying, reducing the demolding process, and thus improving the production efficiency.

[0076] In the embodiments of the present application, the high-temperature carbon residue content of the single-sided adhesive film at 600 °C is less than 0.55%. The high-temperature carbon residue content refers to the mass percentage of the solid carbonaceous residue remaining after the material has undergone evaporation, cracking, and combustion under specific high-temperature conditions. The melting point or ignition point of the embodiments of the present application is lower than 130 °C, and most of it can be completely burned after 300 °C. The high-temperature carbon residue content at 600 °C is measured to be less than 0.55% using the GB / T 17144-1997 Determination Method for Carbon Residue of Petroleum Products (Micro Method).

[0077] Specifically, the main component of the EPE is polyethylene, which is easily decomposed into small molecule gases (such as ethylene and methane) at high temperatures, resulting in a low carbon residue content. The main component of the paper material is cellulose, and a paper material with a carbon residue content less than 0.55% is selected, such as pure wood pulp paper. The material of the mesh yarn is diverse, commonly polyester (PET), nylon (PA), or cotton fiber. In the present invention, synthetic fibers with a low carbon residue content, such as polyester and nylon, can be selected, and their carbon residue content is low. The main components of the UV ink are prepolymers and monomers, which form high molecular polymers after curing, resulting in a low carbon residue content; the material of the cardboard particles is similar to that of the paper material.

[0078] By controlling the high-temperature carbon residue content of the single-sided adhesive film at 600 °C to be less than 0.55% in the embodiments of the present application, the single-sided adhesive film can be completely burned during firing, thus not causing other defects on the glaze surface.

[0079] In an embodiment of the present application, the thickness of the single-sided adhesive film is 0.2 - 0.8 mm.

[0080] Compared with the concave-convex die forming of the ceramic tile back pattern in the embodiments of the present application, since the pressing surface is flat in the present application, the requirement for the height ratio between the fabric layer and the single-sided adhesive film is lower, and the flexural strength of the brick body will not be reduced due to the density difference at the concave-convex parts. Therefore, the thickness of the single-sided adhesive film in the present application can be between 0.2 - 0.8 mm to reduce the production difficulty.

[0081] In the embodiments of the present application, the firing temperature of the ceramic slab body is 1150 - 1220 °C, and the firing time is 45 - 85 minutes.

[0082] In the embodiments of the present application, at a temperature of 1150 - 1220 °C, sufficient solid-phase reactions and liquid-phase sintering occur between the ceramic particles, the particles are more tightly bonded, and the crystal phase structure in the ceramic is also more stable, making it not easy to react with chemical substances such as acids and alkalis, thus improving the ability to resist chemical erosion; the firing time of 45 - 85 minutes not only ensures the firing effect but also improves production efficiency and reduces production costs.

[0083] In an embodiment of the present application, the water content of the production powder used in the fabric layer is 8 - 10%.

[0084] In the embodiment of the present application, the powder material with a moisture content of 8-10% is in a plastic-semi-dry critical state, which can not only maintain the adhesion between powder particles, but also avoid the out-of-control fluidity caused by excessive moisture.

[0085] The present application cleverly uses the pre-designed and pre-customized method to produce a predetermined continuous ultra-large area and large-size roll film (preset and customized according to the size of the specific ceramic rock slab / large slab before firing). The roll film has a three-dimensional relief. The roll film is arranged synchronously with the cloth of the production powder material, and finally the back pattern is obtained by using the ablation principle, which has the following beneficial effects:

[0086] First, the embodiment of the present application improves the problem that ceramic rock slabs and ceramic large slabs are easy to fall off during the wall tiling process, enables them to be fully combined with cement mortar during the tiling process, and improves the safety of ceramic tile tiling.

[0087] Second, the three-dimensional relief material generally exists in a solid form when the temperature is below 60°C, has a melting point or ignition point of 130°C, can mostly volatilize or burn and decompose after exceeding 300°C, and the residual carbon part can also be completely burned at about 600°C during the later firing process. Gas is generated and pores are left during the firing process of the ceramic tile, and the residual carbon content is extremely low, so that other defects of the glaze surface will not be caused.

[0088] Third, the roll film laying mechanism or single-sided / double-sided lamination mechanism added in the embodiment of the present application is a relatively mature device in the ceramic industry, and no additional equipment investment is required.

[0089] Fourth, the single-sided adhesive film in the embodiment of the present application has a certain ductility and stiffness, does not affect the strength of the green body, has a low cost, and is easy to promote.

[0090] The present application also provides a ceramic plate, wherein the ceramic plate is prepared by the method for preparing a roll-pressed ceramic plate as described above.

[0091] The present invention provides a method for preparing a roll-formed ceramic plate and the ceramic plate. The method for preparing the roll-formed ceramic plate includes: preparing a single-sided adhesive film according to a preset back pattern, the single-sided adhesive film including: a single-sided adhesive base film and a three-dimensional relief on one side of the single-sided adhesive base film, the three-dimensional relief being made based on the back pattern; laying the single-sided adhesive film on the roller press, and placing the three-dimensional relief upward; using a feeder of the roller press to distribute a fabric layer on the side of the single-sided adhesive film with the three-dimensional relief, and performing rolling to obtain a ceramic plate blank with the single-sided adhesive base film adhered to the bottom and the three-dimensional relief embedded inside; the ceramic plate blank is dried, glazed and decorated and then fired. During the drying or firing process, the single-sided adhesive film is ablated to form the back pattern at the bottom of the fabric layer, so as to obtain a ceramic plate with the back pattern. This application does not require the use of a mold, does not require demolding, does not require precise control of the angle and depth, the back pattern can be set arbitrarily, the demolding process is reduced, and the production efficiency is improved; moreover, the back pattern with an increased adhesion area can be obtained by using the ablation principle, so that it can be fully combined with cement mortar during the paving process, is not easy to fall off, and improves the stability of the paving of the ceramic tile.

[0092] It should be understood that the application of the present invention is not limited to the above examples. For those of ordinary skill in the art, improvements or changes can be made according to the above description, and all such improvements and changes should fall within the protection scope of the appended claims of the present invention.

Claims

1. A method for preparing a roll-formed ceramic plate, which is realized based on a roll press, characterized in that, The method includes: Preparing a single-sided adhesive film according to a preset back pattern. The single-sided adhesive film includes a single-sided adhesive base film and a three-dimensional relief on one side of the single-sided adhesive base film, and the three-dimensional relief is made based on the back pattern; Laying the single-sided adhesive film on the roll press, with the three-dimensional relief facing upward; Using the fabricator of the roll press to distribute a fabric layer on the side of the single-sided adhesive film with the three-dimensional relief, and performing rolling to obtain a ceramic plate blank with a single-sided adhesive base film adhered to the bottom and a three-dimensional relief embedded inside; The ceramic plate blank is dried, glazed and decorated and then fired. During the drying or firing process, the single-sided adhesive film is ablated to form the back pattern at the bottom of the fabric layer, and a ceramic plate with the back pattern is obtained.

2. The method for preparing a roll-formed ceramic plate according to claim 1, wherein The materials of the single-sided adhesive base film and the three-dimensional relief are both EPE.

3. The method for preparing a roll-formed ceramic plate according to claim 1, characterized in that, The material of the single-sided adhesive base film is a paper material, and the three-dimensional relief is formed by curing the ink printed on the single-sided adhesive base film by a UV printer.

4. The method for preparing a roll-formed ceramic plate according to claim 1, characterized in that, The material of the single-sided adhesive base film is a paper material or a mesh yarn, and the material of the three-dimensional relief is paperboard particles.

5. The method for preparing a roll-formed ceramic plate according to claim 1, wherein A film pulling-out device is arranged at the front end of the fabricator of the roll press; laying the single-sided adhesive film on the roll press, with the three-dimensional relief facing upward, includes: Using the film pulling-out device to flatten the single-sided adhesive film on the steel belt of the roll press, with the three-dimensional relief facing upward.

6. The method for preparing a roll-formed ceramic plate according to claim 1, wherein, The high-temperature carbon residue amount of the single-sided adhesive film at 600 °C is less than 0.55%.

7. The method for preparing a roll-formed ceramic plate according to claim 1, wherein The thickness of the single-sided adhesive film is 0.2 - 0.8 mm.

8. The method for preparing a roll-formed ceramic plate according to claim 1, wherein The firing temperature of the ceramic plate blank is 1150 - 1220 °C, and the firing time is 45 - 85 minutes.

9. The method for preparing a roll-formed ceramic plate according to claim 1, wherein, The moisture content of the production powder used for the fabric layer is 8 - 10%.

10. A ceramic plate, characterized in that, The ceramic plate is prepared by the roll forming method for ceramic plates according to any one of claims 1 - 9.

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