Ceramic colored stone paint process based on sintered sand and manufacturing method thereof

Abstract

The invention relates to the technical field of coatings, in particular to a ceramic colored stone paint process based on sintered sand and a manufacturing method thereof, and the ceramic colored stone paint process comprises preparation of sintered sand, a base material and a pigment bag. The sintered sand is prepared from natural white marble sand, iron oxide pigment, sodium silicate and rubber and plastic C through high-temperature treatment, and has excellent weather resistance and color expressive force; on-site color matching of the pigment bag is realized by matching sintered sand with multiple colors; the base material is composed of water, cellulose, emulsion and the like, and the film coating performance is ensured. According to the invention, 100% sintered sand is adopted as a base material, and the prefabricated pigment bag design is combined, so that the process is simplified, the cost is reduced, the problems of insufficient covering rate, high material consumption, unstable color and the like are solved, and an efficient and environment-friendly solution is provided for building decoration.

Description

Technical Field

[0001] This invention relates to the field of coating technology, specifically to a ceramic stone paint process and its manufacturing method based on sintered sand. Background Technology

[0002] Paint is a mixture of coatings that can firmly cover the surface of an object, serving protective, marking, and other special purposes. With societal development, the performance requirements for building exterior wall decoration materials are gradually increasing. Sintered sand-based ceramic stone paint, due to its excellent decorative effect and weather resistance, has gradually become an important research direction in the field of exterior wall coatings. However, existing sintered sand ceramic stone paints still have certain shortcomings in terms of preparation process, color stability, application performance, and environmental friendliness, affecting their widespread application and market competitiveness.

[0003] A method for preparing low-temperature sintered colored sand, with publication number CN114956866B and publication date April 14, 2023, describes a process where a silica gel primer is formed by initial sintering on a white or light-colored quartz sand surface, followed by a secondary sintering with a high-temperature colorant and a gel-like coloring slurry. Finally, the sand is fixed using a steam method to produce brightly colored and wear-resistant colored sand. However, this technical solution involves multiple sintering and fixing steps, potentially leading to high energy consumption and low production efficiency. Furthermore, the method requires precise control of sintering temperature and time, which may increase process difficulty and cost, limiting its large-scale industrial application.

[0004] A reflective heat-insulating stone-like paint, with publication number CN104356810B and publication date September 21, 2016, is described in this patent. This patent describes a stone-like paint with heat-insulating properties and vibrant colors prepared by mixing reflective heat-insulating sintered sand with water-based polymer emulsions, hollow glass microspheres, and other raw materials. However, the preparation of the reflective heat-insulating sintered sand requires the introduction of expensive functional materials such as nano-antimony tin oxide and nano-indium tin oxide, resulting in high production costs. Furthermore, the stone-like paint may exhibit uneven film thickness during actual application, affecting the consistency of its heat insulation and decorative properties.

[0005] Furthermore, this solution has high requirements for the construction environment, which may limit its practical application. The above issues indicate that existing ceramic stone paints based on sintered sand still have certain shortcomings in terms of color matching during preparation, controllability of production costs, adaptability of construction performance, and environmental friendliness. Summary of the Invention

[0006] This invention relates to the field of coating technology, specifically to a ceramic stone paint based on sintered sand and its preparation process. Addressing the problems of complex preparation processes, insufficient color stability, poor application performance, and lack of environmental friendliness in existing technologies, this invention provides a novel ceramic stone paint and its preparation method, characterized by high hiding power, strong anti-spray properties, reduced material consumption, and long-lasting color stability.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a ceramic stone paint process and its preparation method based on sintered sand, comprising the following weight components: 769.6 parts by weight of sintered sand, 120 parts by weight of water, 1.8 parts by weight of cellulose, 0.5 parts by weight of bentonite, 100 parts by weight of emulsion, 3 parts by weight of ethylene glycol, 4.5 parts by weight of film-forming aid, and 0.6 parts by weight of thickener.

[0008] Preferably, the sintered sand is prepared by the following method: 1000 kg of natural white marble sand and 10 kg of iron oxide pigment are mixed evenly, and then 30 kg of sodium silicate and 10 kg of rubber and plastic C are added respectively. The mixture is stirred until completely uniform, and then the mixture is put into a rotary furnace and heated to 400 degrees Celsius for color fixing treatment. After cooling, sintered sand is obtained.

[0009] Preferably, during the preparation of the sintered sand, the particle size of the natural white marble sand ranges from 0.5 mm to 2 mm.

[0010] Preferably, it also includes a colorant packet, which is made by mixing sintered sand particles of various colors in a specific ratio, with each color of sintered sand particles being mixed in a specific ratio to form a small colorant packet of 3 kg.

[0011] Preferably, the preparation method of the base material is as follows: 120 kg of water is injected into a disperser, and 1.8 kg of cellulose is slowly added under high-speed stirring at 1200 rpm, and stirring is continued for half an hour.

[0012] Preferably, add another 100 kg of emulsion, switch to a low stirring speed of 50 rpm, and stir until the emulsion is completely and evenly dispersed to obtain the base material.

[0013] Preferably, the preparation process of the ceramic stone paint is as follows: 769.6 kg of sintered sand, 100 kg of base material, 0.5 kg of bentonite, 3 kg of ethylene glycol, 4.5 kg of film-forming aid, and 0.6 kg of thickener are added to a mixer in sequence, the mixer is started to mix, and the mixture is mixed until all components are fully homogeneous to obtain the finished ceramic stone paint.

[0014] Preferably, the initial speed of the mixer is 30 revolutions per minute, and after all materials are added, the mixer continues to mix for 30 minutes.

[0015] Preferably, the construction process adopts spraying method for coating, with the spray gun pressure set to 8 to 10KG, the nozzle diameter to 3 to 12 mm, the spraying distance controlled between 50 cm and 100 cm, and the unit amount of paint used being 2.5KG.

[0016] Preferably, the coating film is formed by air drying for 24 hours after the spraying is completed.

[0017] This invention, through the implementation of the above-mentioned technical solution, solves the problems of complex preparation processes, insufficient color stability, poor workability, and lack of environmental friendliness in existing technologies. Using 100% sintered sand as the base material not only simplifies the production process but also significantly reduces energy consumption and production costs.

[0018] In general, ceramic stone paint requires 4KG of paint per square meter during the spraying process. In this invention, white sintered sand is used. The white sintered sand is dyed with white dye, which reduces the transparency rate. Only 2.5KG of paint is needed per square meter.

[0019] The prefabricated colorant packs enable rapid color matching on-site, meeting diverse decorative needs. Simultaneously, the improved overall performance of ceramic stone paint demonstrates significant advantages in terms of coverage, anti-spray properties, and material savings, providing an efficient, economical, and environmentally friendly solution for the architectural decoration field. Detailed Implementation

[0020] This invention provides a technical solution: a ceramic stone paint based on sintered sand and its preparation process. The core of this invention lies in achieving overall optimization of coating performance through the preparation of sintered sand, the design of colorant packets, and the preparation processes of the base material and the finished paint. The specific implementation methods of this invention are described in detail below with reference to actual operating steps.

[0021] First, in the preparation of sintered sand, natural white marble sand is selected as the base material, with its particle size controlled between 0.5-2 mm to ensure particle uniformity. 1000 kg of natural white marble sand and 10 kg of iron oxide pigment are added to a mixing device in a specific ratio. The mixing device is started for initial stirring for 10 minutes at a speed of 60 rpm to ensure uniform pigment distribution. Then, 30 kg of sodium silicate and 10 kg of rubber-plastic C are added sequentially, and stirring continues for 15 minutes at a speed of 80 rpm to ensure thorough mixing of the components. After mixing, the material is transferred to a rotary kiln for high-temperature treatment, with a heating rate controlled at 10°C per minute until the temperature reaches 400°C, which is then maintained at this constant temperature for 30 minutes. This process causes a chemical reaction between the iron oxide pigment, sodium silicate, and rubber-plastic C, forming a dense composite structure layer on the surface of the sand particles. After cooling, the finished sintered sand is obtained. The composite structural layer on the surface of the sintered sand is composed of a glassy substance formed by iron oxide pigment and sodium silicate, as well as toughening components provided by rubber and plastic C. The thickness of this structural layer is about 0.05 mm, and it is tightly bonded to the sand matrix to form a stable physical connection.

[0022] The following is the preparation process of the colorant packets: The sintered sand obtained above is sorted and stored according to color. Multiple colors of sintered sand particles are selected and mixed in a specific ratio, with a total weight of 3 kg, to form a small colorant packet. The colorant packets must be made in a dedicated mixer. The mixer speed is set to 40 rpm, and the mixing time is controlled to 5 minutes to avoid particle breakage due to over-mixing, which would affect the final effect. Each colorant packet is individually packaged for convenient on-site use as needed.

[0023] The preparation of the base material must be strictly carried out according to the following steps: First, inject 120 kg of purified water into a disperser, start the disperser and adjust the speed to 1200 rpm, while slowly adding 1.8 kg of cellulose over 10 minutes to ensure complete dissolution and prevent clumping. Then, continue high-speed stirring for 30 minutes to fully disperse the cellulose in the water and form a uniform colloidal solution. Next, reduce the disperser speed to 50 rpm and slowly add 100 kg of emulsion over 15 minutes to prevent excessive shear force from compromising the stability of the emulsion. After the emulsion is added, continue low-speed stirring for 20 minutes until the emulsion is completely dispersed and forms a stable system with the cellulose solution, yielding the finished base material.

[0024] The preparation process of ceramic stone paint is as follows: First, 769.6 kg of sintered sand is added to a mixer, the mixer is started and the speed is adjusted to 30 rpm to ensure initial uniform mixing. Then, 100 kg of base material, 0.5 kg of bentonite, 3 kg of ethylene glycol, 4.5 kg of film-forming aid, and 0.6 kg of thickener are added sequentially, with a 5-minute interval between each material addition to ensure even distribution of each component. After all materials are added, stirring continues for 30 minutes until all components are fully mixed to form a uniform slurry, which is the finished ceramic stone paint.

[0025] In actual construction: First, open the pre-made colorant packet (3kg) and pour it into the white base material (pre-made white ceramic stone paint). Use an electric mixer to stir at 800 rpm for 5 minutes to fully mix the sintered sand particles in the colorant packet with the base material, forming the desired color of ceramic stone paint. During construction, spraying is used. The spray gun pressure is set to 8-10KG, the nozzle diameter to 3-12 mm, and the spraying distance is controlled between 50 cm and 100 cm. The unit paint consumption is 2.5KG. During spraying, the sintered sand particles adhere evenly to the wall surface under the spraying pressure. Due to the good adhesion of the dense composite structure layer on the surface of the sintered sand, it can form a strong bond with the emulsion in the base material. After spraying, allow it to dry naturally for 24 hours to form a complete coating film.

[0026] In this invention, the composite structural layer generated by the high-temperature treatment of sintered sand interacts with the emulsion in the base material. Polymer molecules in the emulsion penetrate into the micropores of the composite structural layer, forming a mechanical interlocking effect. Simultaneously, bentonite acts as a thixotropic agent in the base material; its plate-like structure forms a three-dimensional network during stirring, endowing the ceramic stone paint with excellent application properties. Ethylene glycol and film-forming aids work synergistically; ethylene glycol lowers the film-forming temperature, while the film-forming aid promotes the fusion of emulsion particles. Together, they enable the coating to form a complete and continuous film layer at a relatively low temperature. The thickener regulates the rheological properties of the ceramic stone paint through intermolecular hydrogen bonding, ensuring that it neither flows nor loses its sprayability during application.

[0027] As can be seen from the above specific embodiments, this invention achieves a comprehensive improvement in the performance of ceramic stone paint through a special preparation process for sintered sand, a precise proportioning design for colorant packets, and a scientific preparation process for the base material and finished paint. Each step and parameter in the entire preparation process is strictly controlled to ensure the stability and consistency of product performance.

[0028] To enable those skilled in the art to fully understand and implement this invention, the specific implementation principle of this invention will be further explained below in conjunction with a specific application scenario.

[0029] In the preparation of sintered sand, natural white marble sand is first selected as the base material and added to a mixing device along with iron oxide pigment in a specific ratio. Initial stirring ensures the pigment adheres evenly to the surface of the sand particles. Subsequently, sodium silicate and rubber-plastic C are added, and stirring continues to ensure thorough integration of the components. The mixed material is then transferred to a rotary kiln for high-temperature treatment at a rate of 10°C per minute until the temperature reaches 400°C and is held constant for 30 minutes. This process induces a chemical reaction between the iron oxide pigment, sodium silicate, and rubber-plastic C, generating a dense composite structural layer approximately 0.05 mm thick. This layer, composed of glassy substances and toughening components, significantly improves the weather resistance and wear resistance of the sand particles while enhancing their adhesion to the base material. The resulting sintered sand, after cooling, possesses excellent physical properties, laying a solid foundation for the subsequent preparation of ceramic stone paint.

[0030] In the preparation of the colorant packets, sintered sand particles of different colors are mixed in a specific ratio, with the total weight controlled at 3kg. Low-speed mixing using a dedicated mixer avoids particle breakage caused by over-mixing. Each colorant packet is individually packaged for easy on-site use according to actual needs. This design not only simplifies the construction process but also effectively avoids color difference problems that may occur during traditional manual mixing, ensuring the consistency and stability of the final coating color.

[0031] In the preparation of the base material, pure water is first injected into a disperser, and cellulose is slowly added under high-speed stirring. The gradual dissolution of cellulose forms a uniform colloidal solution, providing a stable medium environment for the subsequent dispersion of the emulsion. The speed is then reduced, and the emulsion is added slowly to prevent the emulsion's stability from being compromised due to excessive shear force. The introduction of the emulsion endows the base material with excellent film-forming properties, further enhancing the water resistance and corrosion resistance of the ceramic stone paint. The addition of bentonite, through its lamellar structure, forms a three-dimensional network structure during stirring, significantly improving the thixotropic properties of the ceramic stone paint, making it easier to spray and less prone to dripping during application.

[0032] In the preparation process of ceramic stone paint, sintered sand is first added to a mixer for initial mixing, followed by the sequential addition of base material, bentonite, ethylene glycol, film-forming aid, and thickener. Each material is added at 5-minute intervals to ensure uniform distribution. After all materials are added, the mixer speed is increased to 60 rpm and stirred continuously for 30 minutes to ensure thorough mixing and the formation of a uniform slurry. During this process, ethylene glycol and the film-forming aid work synergistically to lower the film-forming temperature and promote the fusion of emulsion particles, allowing the coating to form a complete and continuous film at a lower temperature. The appropriate addition of thickener regulates the rheological properties of the ceramic stone paint, ensuring that it does not flow during application while maintaining good sprayability.

[0033] In actual construction, the pre-made colorant package is first opened and poured into the base material. An electric mixer is used to stir at 800 rpm for 5 minutes to ensure thorough mixing of the sintered sand particles in the colorant package with the base material. During spraying, the spray gun pressure is set to 8-10 kg, the nozzle diameter to 3-12 mm, and the spraying distance is controlled between 50-100 cm. The unit paint consumption is 2.5 kg. During spraying, the sintered sand particles adhere evenly to the wall surface under spray pressure, and their dense composite structure layer forms a strong bond with the emulsion in the base material. After spraying, a complete coating film is formed after 24 hours of natural drying. This process, through the special structural design of the sintered sand and the synergistic effect of various additives in the base material, achieves significant advantages in terms of coverage, anti-spray properties, and material savings.

[0034] In general, ceramic stone paint requires 4KG of paint per square meter during the spraying process. In this invention, white sintered sand is used. The white sintered sand is dyed with white dye, which reduces the transparency of the base layer. Only 2KG of paint is needed per square meter.

[0035] As can be seen from the above steps, this invention solves the problems of complex preparation processes, insufficient color stability, poor workability, and lack of environmental friendliness in existing technologies by using a special preparation process for sintered sand, a precise proportioning design for colorant packets, and a scientific preparation process for base materials and finished paints. Each step and parameter in the entire preparation process is strictly controlled to ensure the stability and consistency of product performance, providing an efficient, economical, and environmentally friendly solution for the building decoration field.

[0036] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A ceramic stone lacquer process based on sintered sand and its manufacturing method, characterized in that, It comprises the following components by weight: 769.6 parts by weight of sintered sand, 120 parts by weight of water, 1.8 parts by weight of cellulose, 0.5 parts by weight of bentonite, 100 parts by weight of emulsion, 3 parts by weight of ethylene glycol, 4.5 parts by weight of film-forming aid, and 0.6 parts by weight of thickener.

2. The ceramic stone paint process and its manufacturing method based on sintered sand according to claim 1, characterized in that, The sintered sand is prepared by the following method: 1000 kg of natural white marble sand and 10 kg of iron oxide pigment are mixed evenly, and then 30 kg of sodium silicate and 10 kg of rubber and plastic C are added respectively. The mixture is stirred until completely uniform, and then the mixture is put into a rotary furnace and heated to 400 degrees Celsius for color fixation treatment. After cooling, sintered sand is obtained.

3. The ceramic stone paint process and its manufacturing method based on sintered sand according to claim 2, characterized in that, In the preparation of the sintered sand, the particle size of the natural white marble sand ranges from 0.5 mm to 2 mm.

4. The ceramic stone paint process and its manufacturing method based on sintered sand according to claim 1, characterized in that, It also includes colorant packets, which are made by mixing sintered sand particles of various colors in a specific ratio, with each color of sintered sand particles mixed in a specific ratio to form a small colorant packet of 3 kg.

5. The ceramic stone paint process and its manufacturing method based on sintered sand according to claim 1, characterized in that, The preparation method of the base material is as follows: 120 kg of water is injected into a disperser, and 1.8 kg of cellulose is slowly added under high-speed stirring at 1200 rpm, and stirring is continued for half an hour.

6. The ceramic stone paint process and its manufacturing method based on sintered sand according to claim 5, characterized in that, Add another 100 kg of emulsion and switch to a low stirring speed of 50 rpm until the emulsion is completely and evenly dispersed to obtain the base material.

7. The ceramic stone paint process and its manufacturing method based on sintered sand according to claim 1, characterized in that, The preparation process of the ceramic stone paint is as follows: 769.6 kg of sintered sand, 100 kg of base material, 0.5 kg of bentonite, 3 kg of ethylene glycol, 4.5 kg of film-forming aid, and 0.6 kg of thickener are added to a mixer in sequence, and the mixer is started to mix until all components are fully homogeneous, so as to obtain the finished ceramic stone paint.

8. The ceramic stone paint process and its manufacturing method based on sintered sand according to claim 7, characterized in that, The initial speed of the mixer is 30 revolutions per minute. After all materials are added, the mixer continues to mix for 30 minutes.

9. The ceramic stone paint process and its manufacturing method based on sintered sand according to claim 1, characterized in that, The construction process uses spraying for coating. The spray gun pressure is set to 8 to 10 kg, the nozzle diameter is 3 to 12 mm, the spraying distance is controlled between 50 cm and 100 cm, and the unit amount of paint used is 2.5 kg.

10. The ceramic stone paint process and its manufacturing method based on sintered sand according to claim 9, characterized in that, After the spraying is completed, the coating is allowed to dry naturally for 24 hours to form a complete film.