Ultra-light, sound-absorbing and heat-insulating soft porcelain and preparation method thereof

Abstract

The invention relates to the technical field of decorative materials, in particular to ultra-light, sound-absorbing and heat-insulating soft porcelain and a preparation method thereof. The ultra-light, sound-absorbing and heat-insulating soft porcelain is prepared from the following raw materials in parts by weight: 120 to 145 parts of compound polymer emulsion, 190 to 230 parts of inorganic matrix, 280 to 350 parts of quartz sand, 70 to 140 parts of hollow microspheres, 2 to 4 parts of bentonite, 7 to 11 parts of flame retardant, 2 to 4 parts of chopped fiber, 0.5 to 1.5 parts of wetting dispersant, 0.1 to 0.5 part of organic silicon defoaming agent, 0.5 to 2 parts of inorganic pigment and 200 to 240 parts of diluent. The ultra-light, sound-absorbing and heat-insulating soft porcelain is prepared through segmented baking, ordered feeding and low-speed stirring technologies, the triple targets of ultra-light weight, heat insulation and sound absorption are achieved, and the water absorption rate, durability and flexibility far exceed the standard requirements.

Description

Technical Field

[0001] This invention relates to the field of decorative materials technology, and in particular to an ultralight, sound-absorbing and heat-insulating soft porcelain and its preparation method. Background Technology

[0002] Flexible ceramic tile is a new type of building decoration material made primarily of modified inorganic mineral powder, mixed with a small amount of water-based polymer, and formed through low-temperature baking. The finished product combines the durability of inorganic materials with the flexibility of organic materials. Compared to traditional ceramic tiles, flexible ceramic tile has significant advantages such as being lightweight, thin, flexible, easy to bend, easy to install, rich in colors, and having realistic textures. It is a new type of building material sheet product that integrates decoration, safety and environmental protection, fire resistance, and excellent aging resistance. It can be widely used in interior and exterior building decoration and can be applied to curved surfaces.

[0003] Despite its outstanding decorative and workability features, flexible ceramic tiles have become increasingly limited as market demands for functional building materials rise, particularly in acoustic and thermal performance: ① Insufficient sound insulation and absorption: Traditional flexible ceramic tiles have a dense structure, lacking porous or resonant sound-absorbing structures. Their acoustic impedance differs significantly from air, resulting in strong reflection and weak absorption, making it difficult to dissipate sound energy. This limits their application in quiet environments such as conference rooms and cinemas, or other acoustically demanding settings. ② Poor thermal insulation: The main component of flexible ceramic tiles is inorganic mineral powder. While its thermal conductivity is lower than traditional ceramics, it is still relatively high, making it a poor conductor of heat. This makes it difficult to block heat transfer and meet the high requirements for thermal insulation in building envelopes for energy conservation. ③ The increasing size requirements of decorative products mean increased weight per piece. This necessitates more on-site construction workers, requires stronger adhesion and anti-slip properties for adhesives, and addresses issues such as the need for auxiliary nails for localized fixation.

[0004] Therefore, developing an ultra-lightweight flexible ceramic that also provides excellent sound absorption and heat insulation properties for large-sized flexible ceramics has become a pressing technical challenge for the industry. Summary of the Invention

[0005] To meet the requirements of large-size flexible ceramic tiles that are lightweight and easy to install, and have good sound insulation and heat insulation properties, this application provides an ultra-lightweight, sound-absorbing and heat-insulating flexible ceramic tile and its preparation method.

[0006] In the first aspect, this application provides an ultralightweight, sound-absorbing, and heat-insulating flexible ceramic material, employing the following technical solution: An ultralightweight, sound-absorbing, and heat-insulating flexible ceramic is made from the following raw materials in parts by weight: 120-145 parts of compound polymer emulsion, 190-230 parts of inorganic matrix, 280-350 parts of quartz sand, 70-140 parts of hollow microspheres, 2-4 parts of bentonite, 7-11 parts of flame retardant, 2-4 parts of chopped fibers, 0.5-1.5 parts of wetting and dispersing agent, 0.1-0.5 parts of organosilicon defoamer, 0.5-2 parts of inorganic pigment, and 200-240 parts of diluent.

[0007] By adopting the above scheme, the resulting ultra-lightweight, sound-absorbing, and heat-insulating soft porcelain achieves a 40-60% reduction in unit weight by reducing the proportion of heavy calcium carbonate powder and adding lightweight composite functional fillers, hollow microspheres, and physical foaming agents, while maintaining the original thickness. The addition of hollow microspheres with a spherical structure makes spraying easier and reduces strength. The resulting density is as low as 720 kg / m³, with a thermal conductivity of only 0.039 W / (m·K) and an NRC value of 0.55, achieving the triple goals of "ultra-lightweight, heat-insulating, and sound-absorbing." Simultaneously, water absorption, durability, and flexibility meet or even far exceed standard requirements.

[0008] Preferably, the compounded polymer emulsion is prepared by mixing an aqueous acrylic emulsion and an ethylene-vinyl acetate emulsion in a mass ratio of (6-8):(2-4).

[0009] By adopting the above scheme, a compounded polymer emulsion is used as an organic binder phase to encapsulate inorganic materials and form a film, providing the product with flexibility and basic strength. In the above compounding scheme, the water-based acrylic emulsion (AC) provides the product with the main basic strength, durability and surface properties. The high proportion ensures that the flexible ceramic can resist ultraviolet rays, rain and temperature changes during long-term use and maintain stable performance, which is especially suitable for exterior wall applications. The ethylene-vinyl acetate (VAE) emulsion, as the "ribs and binding core" of the composite emulsion, has extremely strong adhesion to effectively bind a large amount of inorganic powder and lightweight filler together, preventing the strength reduction caused by excessive filler or foaming.

[0010] Preferably, the inorganic matrix is ​​prepared by mixing heavy calcium carbonate powder, calcined kaolin and S95 mineral powder in a mass ratio of (30-40):(40-50):(120-140).

[0011] By employing the above scheme, using S95 mineral powder as the strength and structural foundation, calcined kaolin as a functional regulator and connector, and heavy calcium carbonate powder as a basic filler and volume supplement, a dense, stable, high-strength, and highly processable inorganic framework is constructed. The S95 mineral powder particles are extremely fine, fully filling the spaces between the emulsion and polymer segments, resulting in a denser overall structure. S95 mineral powder contains a large amount of amorphous active silica and alumina, which, during the drying process and subsequent use, can undergo a "secondary hydration reaction" with moisture in the system and trace alkaline substances produced by emulsion decomposition, generating hydrated calcium silicate gel similar to cement hydrates. The micron-sized sheet-like structure of calcined kaolin acts like layers of "small cards" in the system, effectively overlapping and interweaving to improve the material's barrier properties (positively blocking water vapor, heat, and sound waves) and provide a certain toughening effect.

[0012] Preferably, the hollow microspheres are either hollow glass microspheres or hollow ceramic microspheres.

[0013] By adopting the above solution, hollow microspheres are the core material for achieving breakthroughs in lightweight functionality. Through their unique hollow closed structure, they simultaneously solve the two major problems of lightweighting and thermal insulation.

[0014] Preferably, the flame retardant is either aluminum hydroxide or magnesium hydroxide.

[0015] By adopting the above scheme, aluminum hydroxide and magnesium hydroxide, as flame retardants, are non-toxic, smoke-suppressing, environmentally friendly, inexpensive, and have high whiteness without affecting product coloring. They achieve flame retardancy by endothermic decomposition and the release of water vapor, while also having smoke-suppressing and filling functions. The decomposition temperature of aluminum hydroxide is 180-200℃, and that of magnesium hydroxide is 340-350℃. With a preparation process temperature below 140℃, aluminum hydroxide is the better choice.

[0016] Preferably, the chopped fiber is a polypropylene monofilament fiber with a length of 3 mm.

[0017] By adopting the above scheme, polypropylene monofilament fibers are characterized by high strength, high modulus, easy dispersion, non-agglomeration, and corrosion resistance, providing soft ceramic products with good crack resistance and flexibility.

[0018] Preferably, the wetting and dispersing agent is a mixture of polycarboxylic acid dispersant and fatty alcohol polyoxyethylene ether wetting agent in a mass ratio of (2-4):1.

[0019] By adopting the above scheme, the synergistic effect of wetting and dispersing agents ensures that the slurry achieves extremely high uniformity and fineness in a short time, without "fish eyes" or particle agglomeration; the resulting slurry has good fluidity and stable viscosity, which is very beneficial to the subsequent spraying process and can form a smooth and uniform wet film.

[0020] Preferably, the silicone defoamer is a modified silicone polyether emulsion.

[0021] By adopting the above scheme, the dispersion effect of inorganic powders is excellent and the versatility is strong; the aqueous polymer emulsion has good compatibility and good wettability to porous materials (such as aerogels) and lightweight fillers (such as hollow microspheres). The modified organosilicon polyether emulsion has strong defoaming ability and is not prone to surface defects (such as shrinkage cavities), and has good compatibility with aqueous systems.

[0022] Preferably, the inorganic pigment is one or more of the following: iron oxide red, iron oxide yellow, iron oxide black, iron oxide brown, titanium dioxide, chrome green, and phthalocyanine blue.

[0023] Preferably, the diluent is water.

[0024] Preferably, the ultralight, sound-absorbing and heat-insulating soft ceramic also includes 15-35 parts of composite lightweight functional filler, which is prepared by mixing silica aerogel and expanded perlite in a mass ratio of (2-4):(1-3).

[0025] By adopting the above-mentioned scheme, silica aerogel, a solid material with low density and thermal conductivity, and expanded perlite ultrafine powder, a porous and lightweight material, provide support for the system. The aerogel powder fills the spaces between the perlite particles and within its own pores. This "micron-nano" dual-pore structure greatly increases the complexity of the heat conduction path, achieving an ultimate thermal insulation effect. Simultaneously, expanded perlite has numerous open and interconnected micropores, providing excellent entry channels and energy dissipation space for sound waves. The nanoscale pores of silica aerogel have excellent absorption properties for high-frequency sound waves, especially broadening the absorption range for mid- and low-frequency sound waves, thereby significantly improving the product's noise reduction coefficient. This scheme cleverly utilizes the composite of nanomaterials (silica aerogel) and micromaterials (expanded perlite) to construct a multi-level porous structure, simultaneously overcoming the three major technical challenges of lightweight, thermal insulation, and sound absorption. The technical approach has outstanding and substantial characteristics.

[0026] Preferably, the ultralight, sound-absorbing and heat-insulating flexible ceramic also includes a chemical foaming agent, which is 1-3 parts of azodicarbonamide.

[0027] Preferably, the ultralight, sound-absorbing and heat-insulating soft ceramic also includes a physical foaming agent, which is 2-5 parts of thermal expansion microspheres.

[0028] By employing the above scheme, chemical foaming agents are combined with physical foaming agents. Chemical foaming—azodicarbonamide (AC) decomposes at a relatively low temperature (80-110℃), producing gases such as nitrogen and carbon monoxide, forming the basic foaming matrix and open-cell structure. Physical foaming—thermally expanding microspheres—are heated at a higher temperature (100-130℃), causing their outer shell to soften and the internal liquid hydrocarbons to vaporize, forming "balloons" that expand into hollow closed-cell microspheres. The two-stage foaming and expansion process results in extremely high gas introduction efficiency, thereby reducing the apparent density of the product to an extremely low level. The uniformly dispersed closed cells of the thermally expanding microspheres effectively block heat conduction and convection, reducing the thermal conductivity of the product. The open and interconnected pores formed by chemical foaming allow sound waves to smoothly enter the interior of the material, where they are repeatedly reflected and rubbed in these tortuous channels, converting sound energy into heat energy and dissipating it. This achieves an ultra-lightweight product and is also the core structural design that synergistically enhances thermal insulation and sound absorption performance.

[0029] Secondly, this application provides a method for preparing ultralightweight, sound-absorbing, and heat-insulating flexible porcelain, employing the following technical solution: S1 Weigh the raw materials according to the proportion, mix and stir for 5-10 minutes until uniformly dispersed, and prepare a uniform slurry; S2 involves spraying the slurry from S1 onto the surface of a silicone mold, creating a wet film thickness of 1-2 mm; then drying it in a low-temperature drying tunnel at 60-90℃ for 1-2 hours to obtain a primary substrate. S3 is a secondary spray coating on the substrate of S2. Immediately after spraying, the fiber mesh cloth is laid on it, and the surface is lightly pressed and flattened with a roller press device to control the wet film thickness to 1-2mm. Then it enters the second high temperature drying tunnel at 80-120℃ for 1.5-2 hours to dry. After S4 is taken out of the furnace, it immediately enters the air-cooling section to reduce its temperature to below 50°C; The S5 is peeled off from the mold, cut, and its performance is tested. Qualified products are then packaged and put into storage.

[0030] Preferably, in step S1, the raw materials are weighed in proportion, and the compounded polymer emulsion, inorganic matrix, quartz sand, bentonite, flame retardant, short fiber, wetting and dispersing agent, organosilicon defoamer, inorganic pigment and diluent are mixed and stirred for 5-8 minutes. Then, composite lightweight functional filler, hollow microspheres and physical foaming agent are added and stirred at low speed for 1-2 minutes until uniformly dispersed to prepare a uniform slurry.

[0031] Preferably, the fiber mesh is an alkali-resistant fiber mesh.

[0032] By adopting the above scheme, precise temperature control is achieved through segmented baking. In the first low-temperature baking tunnel, azodicarbonamide decomposes, generating gas that initially foams and sets the slurry, forming a basic porous framework. The second high-temperature baking tunnel activates physical foaming—thermal expansion microspheres expand under heat within this temperature range, forming uniform, closed micropores, achieving secondary foaming and resulting in the final product thickness and high lightweight. At this temperature, the polymer emulsion coalesces into a film, firmly binding the inorganic powder and functional fillers, giving the product its final strength. Rapid cooling helps stabilize the foamed structure and prevent deformation. The feeding sequence and low-speed stirring effectively prevent the crushing of hollow microspheres and the destruction of the silica aerogel nanostructure, ensuring the effectiveness of the functional fillers. Segmented heating achieves sequential control of chemical and physical foaming, constructing a multi-level gradient pore structure with both open and closed pores. This is the fundamental guarantee for the product to achieve its three major functions: ultra-lightweight, sound absorption, and heat insulation. Simultaneously, segmented baking replaces simple, long-term drying, making the process more scientific, energy-efficient, and resulting in more stable product quality.

[0033] In summary, this application has the following beneficial effects: 1. The ultra-lightweight, sound-absorbing, and heat-insulating flexible ceramic of this application has a density as low as 720 kg / m³. 3 With a thermal conductivity of only 0.039 W / (m·K) and an NRC value of 0.55, it achieves the triple goals of "ultra-lightweight, heat insulation, and sound absorption". At the same time, its water absorption rate, durability, and flexibility meet or even far exceed the standard requirements.

[0034] 2. The ultralightweight, sound-absorbing, and heat-insulating flexible ceramic of this application reduces the proportion of heavy calcium carbonate powder and adds lightweight materials such as composite lightweight functional fillers, hollow microspheres, and physical foaming agents. Based on the original thickness, the unit weight is reduced by 40-60%, making it lighter and aligning with the technological development trend of lightweight and environmentally friendly materials. The addition of hollow microspheres with a spherical structure makes spraying easier and reduces strength requirements. For larger products (such as 1.2*3m flexible ceramics) or even larger, it improves safety and practicality. It reduces the difficulty of on-site construction and installation, increasing labor efficiency. It also reduces transportation costs. Furthermore, the introduction of chemical and physical foaming enhances the product's sound absorption and heat insulation properties, improving its additional functions.

[0035] 3. The preparation method of the ultralightweight, sound-absorbing and heat-insulating soft porcelain of this application, by adopting the above scheme, through segmented baking and precise temperature control, perfectly realizes the time sequence control of chemical foaming and physical foaming, and constructs a multi-level gradient pore structure with "open pores-closed pores" coexisting. This is the fundamental guarantee for the product to achieve the three major functions of ultralightweight, sound absorption and heat insulation. At the same time, segmented baking replaces simple long-term drying, making the process more scientific, energy consumption lower, and product quality more stable. Through the feeding sequence and low-speed stirring, the crushing of hollow microspheres and the destruction of silica aerogel nanostructure are effectively avoided, ensuring the effect of functional filler. Detailed Implementation

[0036] The technical solution of this application is further illustrated by specific embodiments below. These specific embodiments do not represent a limitation on the scope of protection of this application. Any non-essential modifications and adjustments made by others based on the concept of this application still fall within the scope of protection of this application.

[0037] Unless otherwise specified, the experimental methods shown in the following examples are conventional methods. All reagents and materials shown are commercially available products.

[0038] Aqueous acrylic emulsion: Dow Chemical, model: AC-261P; Ethylene-vinyl acetate emulsion: Shandong Yuke Chemical Co., Ltd., Model: BJ-707, Item No.: RY01; Heavy calcium carbonate powder: Lingshou County Hengyang Mineral Products Processing Plant, Item No.: HY-956231; Calcined kaolin: Lingshou County Hengyang Mineral Products Processing Plant, item number: 0324; S95 mineral powder: Taixing Suye New Building Materials Co., Ltd., Product No.: mineral powder; Quartz sand: Lingshou County Hengyang Mineral Products Processing Plant, item number: 558988; Hollow glass microspheres: Lingshou County Rijin Mineral Products Processing Plant, Item No.: RL38; Hollow ceramic microspheres: Foshan Yanzhirui Hardware Abrasives Co., Ltd., Model: B40; Aluminum hydroxide: Tuoyi New Materials (Guangzhou) Co., Ltd., Model: TY-15; Magnesium hydroxide: Hefei Zhongke Flame Retardant New Materials Co., Ltd., Model: 2810; Polypropylene fiber: Langfang Feitai New Material Technology Co., Ltd., Item No.: 11205, Model: 0015; Polyacrylate dispersant: Dow Chemical, Model: ACUSOL 445N, Part No.: UT001; Fatty alcohol polyoxyethylene ether wetting agents: Zhengzhou Chaoxin Chemical Products Co., Ltd., Product Name: AEO-9, Model: CAB-35, Item No.: 096-12; Modified silicone polyether emulsion; BYK®-024, Germany; BYK Chemicals, Germany. Silica aerogel: Hebei Fangji New Material Technology Co., Ltd., Item No.: 6698; Expanded perlite: Lingshou County Ze'en Mineral Products Processing Plant, Item No.: zzy-o01; Thermal expansion microspheres: AkzoNobel EXPANCEL, model: 930DU120; The present application will be further described in detail below with reference to embodiments and comparative examples.

[0039] Example 1 A method for preparing ultralightweight, sound-absorbing, and heat-insulating flexible porcelain, employing the following technical solution: S1 weighs the raw materials according to the proportion, first mixes the compounded polymer emulsion, inorganic matrix, quartz sand, bentonite, flame retardant, short fiber, wetting and dispersing agent, organosilicon defoamer, inorganic pigment and diluent, stirs for 7 minutes, then adds composite lightweight functional filler, hollow microspheres and physical foaming agent, stirs at low speed for 2 minutes until uniformly dispersed, and prepares a uniform slurry; S2 involves spraying the slurry from S1 onto the surface of a silicone mold, creating a wet film thickness of 2 mm; then drying it in a low-temperature drying tunnel at 80°C for 1.5 hours to obtain a primary foamed matrix. S3 is a secondary spray coating on the primary foamed substrate of S2. Immediately after spraying, the fiber mesh cloth is laid on it, and the surface is lightly pressed and flattened with a roller press device to control the wet film thickness to 2mm. It is then dried in a second-stage high-temperature drying tunnel at 120℃ for 2 hours. After S4 is taken out of the furnace, it immediately enters the air-cooling section to reduce its temperature to below 50°C; The S5 is peeled off from the mold, cut, and its performance is tested. Qualified products are then packaged and put into storage.

[0040] The composition and dosage of the ultralightweight, sound-absorbing, and heat-insulating flexible ceramic are shown in Table 1. Table 1. Component dosage (kg) of metal-plastic bonding aids in Examples 1-8 The wetting and dispersing agent is prepared by mixing a polycarboxylic acid dispersant and a fatty alcohol polyoxyethylene ether wetting agent in a mass ratio of 3:1, specifically 1.2 kg of polycarboxylic acid dispersant (Targon® 1124) and 0.4 kg of fatty alcohol polyoxyethylene ether wetting agent (AEO-9).

[0041] Example 2 A method for preparing an ultralightweight, sound-absorbing, and heat-insulating flexible ceramic, which differs from Example 1 in that: S1 Weigh the raw materials according to the proportion, first mix the compounded polymer emulsion, inorganic matrix, quartz sand, bentonite, flame retardant, short fiber, wetting and dispersing agent, organosilicon defoamer, inorganic pigment and diluent, stir for 5 minutes, then add hollow microspheres and stir at low speed for 1 minute until uniformly dispersed to prepare a uniform slurry. S2 involves spraying the slurry from S1 onto the surface of a silicone mold, achieving a wet film thickness of 1 mm; then drying it in a low-temperature drying tunnel at 60°C for 1 hour to obtain a primary substrate. S3 is a secondary spray coating on the substrate of S2. Immediately after spraying, the fiber mesh cloth is laid on it, and the surface is lightly pressed and flattened with a roller press device to control the wet film thickness to 1mm. It is then dried in a second-stage high-temperature drying tunnel at 110℃ for 1.5h. After S4 is taken out of the furnace, it immediately enters the air-cooling section to reduce its temperature to below 50°C; The S5 is peeled off from the mold, cut, and its performance is tested. Qualified products are then packaged and put into storage.

[0042] The composition and dosage of the ultralight, sound-absorbing, and heat-insulating soft ceramic are shown in Table 1.

[0043] The wetting and dispersing agent is prepared by mixing a polycarboxylic acid dispersant and a fatty alcohol polyoxyethylene ether wetting agent at a mass ratio of 2:1, specifically 0.8 kg of polycarboxylic acid dispersant (Targon® 1124) and 0.4 kg of fatty alcohol polyoxyethylene ether wetting agent (AEO-9).

[0044] Example 3 A method for preparing an ultralightweight, sound-absorbing, and heat-insulating flexible ceramic, which differs from Example 1 in that: S1 Weigh the raw materials according to the proportion, first mix the compounded polymer emulsion, inorganic matrix, quartz sand, bentonite, flame retardant, short fiber, wetting and dispersing agent, organosilicon defoamer, inorganic pigment and diluent, stir for 8 minutes, then add hollow microspheres and stir at low speed for 1 minute until uniformly dispersed to prepare a uniform slurry. S2 involves spraying the slurry from S1 onto the surface of a silicone mold, achieving a wet film thickness of 2 mm; then drying it in a low-temperature drying tunnel at 60°C for 2 hours to obtain a primary substrate. S3 is a second-stage spray coating on the substrate of S2. Immediately after spraying, the fiber mesh cloth is laid on it, and the surface is lightly pressed and flattened with a roller press device to control the wet film thickness to 1mm. It is then dried in the second-stage high-temperature drying tunnel at 80℃ for 2 hours. After S4 is taken out of the furnace, it immediately enters the air-cooling section to reduce its temperature to below 50°C; The S5 is peeled off from the mold, cut, and its performance is tested. Qualified products are then packaged and put into storage.

[0045] The composition and dosage of the ultralight, sound-absorbing, and heat-insulating soft ceramic are shown in Table 1.

[0046] Examples 4-8 A method for preparing an ultralight, sound-absorbing and heat-insulating soft porcelain, which differs from Example 1 in that the component amounts of the ultralight, sound-absorbing and heat-insulating soft porcelain are shown in Table 1.

[0047] The wetting and dispersing agent is prepared by mixing a polycarboxylic acid dispersant and a fatty alcohol polyoxyethylene ether wetting agent at a mass ratio of 4:1, specifically 1.6 kg of polycarboxylic acid dispersant (Targon® 1124) and 0.4 kg of fatty alcohol polyoxyethylene ether wetting agent (AEO-9). Comparative Example

[0048] Comparative Example 1 The difference from Example 8 is that only chemical foaming was used: only 2 kg of azodicarbonamide was added, and no physical foaming agent was added.

[0049] Comparative Example 2 The difference from Example 8 is that only physical foaming was used: only 3.7 kg of thermally expanding microspheres were added, and no chemical foaming agent was added.

[0050] Comparative Example 3 The difference from Example 8 is that in the composite lightweight functional filler, the mass ratio of SiO2 aerogel to expanded perlite is 4:1, and the specific addition amount is 20 kg of SiO2 aerogel and 5 kg of expanded perlite.

[0051] Comparative Example 4 The difference from Example 8 is that in the composite lightweight functional filler, the mass ratio of SiO2 aerogel to expanded perlite is 1:3, and the specific addition amount is 5 kg of SiO2 aerogel and 15 kg of expanded perlite.

[0052] Comparative Example 5 The difference from Example 8 is that 25 kg of heavy calcium carbonate powder was used instead of the composite lightweight functional filler (15 kg of SiO2 aerogel and 10 kg of expanded perlite).

[0053] Comparative Example 6 The difference from Example 8 is that the emulsion type is singular, using only 130 kg of AC emulsion and completely omitting VAE emulsion.

[0054] Comparative Example 7 The difference from Example 8 is that the baking temperature of S2 and S3 is uniformly set to 100°C.

[0055] Comparative Example 8 The difference from Example 8 is that mineral wool fiber is used instead of composite functional filler: 25 kg of rock wool short fiber is used instead of 15 kg of aerogel and 10 kg of expanded perlite. Performance testing

[0056] The tests for appearance quality defects, dimensional deviations, water absorption, frost resistance, heat resistance, stain resistance, chemical corrosion resistance, artificial aging resistance, and flexibility were conducted in accordance with JC / T 2219-2014(2017) "Modified Inorganic Powder Composite Building Facing Sheets"; the testing standards are shown in Table 2. Table 2 Performance Testing Standards The ultralight, sound-absorbing and heat-insulating soft ceramics prepared in Examples 1-8 and Comparative Examples 1-8 were subjected to the above performance tests, and the test results are shown in Table 3.

[0057] Table 3 Performance test results of Examples 1-8 and Comparative Examples 1-8 As can be seen from the performance test results in Table 3, changes in each component in the formula directly affect the performance of the final product.

[0058] Examples 1-3 do not use functional fillers and foaming agents. By reducing the amount of heavy fillers and increasing the amount of light fillers (hollow microspheres), the density and thermal insulation of the products are improved to a certain extent.

[0059] Examples 4-5 fixed other components and changed the ratio of AC / VAE emulsion. Example 4 had a high VAE content, good flexibility, and strong adhesion, so the density and heat insulation were slightly improved. Example 5 had a high AC content, the film was harder, the weather resistance was better, and the overall performance was comparable to Example 4.

[0060] Examples 6-8, based on Example 1, introduced silica aerogel, expanded perlite, chemical foaming agent, and physical foaming agent. The proportion of functional fillers significantly affected the performance. The density of Example 6 dropped sharply from 1050 kg / m³ in Example 1 to 850 kg / m³, indicating that the effect of the dual-mode foaming agent began to appear, with gas replacing part of the solid volume. The thermal conductivity decreased from 0.160 W / m·K to 0.065 W / m·K, significantly improving thermal insulation, indicating that the nanopores of silica aerogel and the micropores formed by foaming together constructed a highly efficient thermal barrier. The noise reduction coefficient decreased from 0.15 NRC to 0.40 NRC, doubling the sound absorption, indicating that the open pores formed by chemical foaming and the porous structure of perlite provided sound wave dissipation channels.

[0061] Example 8 exhibits excellent performance across all indicators, with a density as low as 720 kg / m³, a thermal conductivity of only 0.039 W / (m·K), and an NRC value of 0.55, successfully achieving the triple goals of "ultra-lightweight, heat insulation, and sound absorption." Simultaneously, its water absorption, durability, and flexibility meet or even far exceed standard requirements, demonstrating the superior performance of the entire technical solution.

[0062] Comparative Examples 1 and 2 both outperformed Comparative Example 1, but were inferior to Example 8. Comparative Example 1 (chemical foaming) had more open pores, resulting in slightly better sound absorption but poorer heat insulation. Comparative Example 2 (physical foaming only) had more closed pores, resulting in slightly better heat insulation but insufficient sound absorption. This demonstrates the necessity of the dual-mode foaming system in the synergistic functional structure of heat insulation and sound absorption.

[0063] Comparative Example 3 has excellent thermal insulation but is expensive and has reduced mechanical properties; Comparative Example 4 has good sound absorption and low cost but significantly reduced thermal insulation, proving that the proportions of Example 8 are the optimal way to balance performance and cost.

[0064] Comparative Example 5 showed performance almost identical to Comparative Example 1. Replacing the functional filler with heavy calcium carbonate powder significantly increased the density and completely destroyed the porous structure, leading to the failure of thermal insulation and sound absorption functions, proving that aerogel and perlite cannot be replaced by ordinary fillers.

[0065] Comparative Example 6 used only AC emulsion, which had poor flexibility and cracked. The pure AC emulsion film had high hardness and brittleness and could not withstand bending stress, which proved the key role of the AC / VAE compound emulsion system in obtaining good flexibility.

[0066] Comparative Example 7 sets the baking temperature of S2 and S3 to 100℃. All core functional indicators decrease significantly. The uniform baking temperature cannot allow the two foaming agents to react sequentially at the optimal temperature, resulting in insufficient and uneven foaming and poor pore structure. This proves that the segmented baking process is the key to ensuring successful foaming.

[0067] Comparative Example 8, which used rock wool fiber to replace composite functional filler, exhibited performance imbalances and numerous fatal defects. While rock wool fiber provided good thermal insulation, its high water absorption caused the product's water absorption rate to soar (15.5%), severely exceeding the standard. The fiber's hydrophilicity also compromised the system's stability, resulting in poor freeze-thaw resistance (pulverization). Simultaneously, the flocculent fibers severely hindered foaming, leading to a higher density. Although the fiber's sound-absorbing properties resulted in a higher NRC value, this came at the cost of sacrificing mechanical properties and durability.

[0068] The above test results show that the ultra-lightweight, sound-absorbing and heat-insulating soft porcelain prepared in this application, through multi-component compounding, segmented baking with precise temperature control, feeding sequence and low-speed stirring process, achieves a density as low as 720 kg / m³, a thermal conductivity of only 0.039 W / (m·K), and an NRC value of 0.55, successfully achieving the triple goals of "ultra-lightweight, heat-insulating and sound-absorbing". At the same time, the water absorption rate, durability and flexibility meet or even far exceed the standard requirements.

[0069] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but as long as they are within the scope of the present invention, they are protected by patent law.

Claims

1. A lightweight, sound-absorbing, and heat-insulating flexible ceramic, characterized in that, It is prepared from the following raw materials in parts by weight: 120-145 parts of compound polymer emulsion, 190-230 parts of inorganic matrix, 280-350 parts of quartz sand, 70-140 parts of hollow microspheres, 2-4 parts of bentonite, 7-11 parts of flame retardant, 2-4 parts of chopped fiber, 0.5-1.5 parts of wetting and dispersing agent, 0.1-0.5 parts of organosilicon defoamer, 0.5-2 parts of inorganic pigment, and 200-240 parts of diluent.

2. The ultralightweight, sound-absorbing, and heat-insulating flexible ceramic according to claim 1, characterized in that, The compounded polymer emulsion is prepared by mixing water-based acrylic emulsion and ethylene-vinyl acetate emulsion in a mass ratio of (6-8):(2-4).

3. The ultralightweight, sound-absorbing, and heat-insulating flexible ceramic according to claim 1, characterized in that, The inorganic matrix is ​​prepared by mixing heavy calcium carbonate powder, calcined kaolin and S95 mineral powder in a mass ratio of (30-40):(40-50):(120-140).

4. The ultralightweight, sound-absorbing, and heat-insulating flexible ceramic according to claim 1, characterized in that, The hollow microspheres are either hollow glass microspheres or hollow ceramic microspheres.

5. The ultralightweight, sound-absorbing, and heat-insulating flexible ceramic according to claim 1, characterized in that, The flame retardant is either aluminum hydroxide or magnesium hydroxide.

6. The ultralightweight, sound-absorbing, and heat-insulating flexible ceramic according to claim 1, characterized in that, The wetting and dispersing agent is a mixture of polycarboxylic acid dispersant and fatty alcohol polyoxyethylene ether wetting agent in a mass ratio of (2-4):

1.

7. The ultralightweight, sound-absorbing, and heat-insulating flexible ceramic according to claim 1, characterized in that, It also includes 15-35 parts of composite lightweight functional filler, which is prepared by mixing silica aerogel and expanded perlite in a mass ratio of (2-4):(1-3).

8. The ultralightweight, sound-absorbing, and heat-insulating flexible ceramic according to claim 1, characterized in that, It also includes a chemical foaming agent, namely 1-3 parts of azodicarbonamide.

9. The ultralightweight, sound-absorbing, and heat-insulating flexible ceramic according to claim 1, characterized in that, It also includes a physical foaming agent, consisting of 2-5 parts of thermally expanding microspheres.

10. A method for preparing ultralightweight, sound-absorbing, and heat-insulating flexible porcelain as described in any one of claims 1-9, characterized in that, It includes the following steps: S1 Weigh the raw materials according to the proportion, mix and stir for 5-10 minutes until uniformly dispersed, and prepare a uniform slurry; S2 involves spraying the slurry from S1 onto the surface of a silicone mold, creating a wet film thickness of 1-2 mm; then drying it in a low-temperature drying tunnel at 60-90℃ for 1-2 hours to obtain a primary substrate. S3 is a secondary spray coating on the substrate of S2. Immediately after spraying, the fiber mesh cloth is laid on it, and the surface is lightly pressed and flattened with a roller press device to control the wet film thickness to 1-2mm. Then it enters the second high temperature drying tunnel at 80-120℃ for 1.5-2 hours to dry. After S4 is taken out of the furnace, it immediately enters the air-cooling section to reduce its temperature to below 50°C; The S5 is peeled off from the mold, cut, and its performance is tested. Qualified products are then packaged and put into storage.