A three-dimensional ceramic tile and a manufacturing process thereof

Abstract

The application discloses a kind of stereoscopic ceramic tile and its manufacturing process, including ceramic tile body, T-shaped groove is set in the lower end surface of the four edges of the ceramic tile body, I-beam is set in the inside of the T-shaped groove, locking mechanism is set between the T-shaped groove and I-beam.The application adopts mortise and tenon connection mode, by setting T-shaped groove in the lower end surface of the four edges of the ceramic tile body, and setting I-beam with locking mechanism, when splicing, I-beam is clamped into T-shaped groove and automatically locked by locking mechanism, this structure makes that the ceramic tile body after splicing will not produce displacement in horizontal position and up and down position, compared with traditional paste or simple splicing mode, it greatly improves the structure stability after laying, for example, in ground ceramic tile laying, even if being subjected to personnel walking, furniture moving and other external force, the connection between ceramic tile is still stable, and will not appear loose or displacement.

Description

Technical Field

[0001] This invention relates to the field of tile adhesive, specifically to a three-dimensional tile adhesive and its manufacturing process. Background Technology

[0002] Tile tiling plays a vital role in modern architectural decoration. Whether in residential, commercial, or public buildings, tile tiling is widely used for wall and floor decoration. It not only provides an aesthetically pleasing appearance but also offers functional benefits such as waterproofing and wear resistance. As people's demands for architectural decoration continue to rise, higher requirements are being placed on the performance and decorative effects of tile tiling.

[0003] In existing tile-laying techniques, traditional tile-laying primarily employs a simple adhesive method. For example, tiles are directly pasted onto walls or floors using cement mortar or ordinary glue. This connection method lacks effective horizontal restraint structures, making the tiles prone to horizontal displacement under external forces. Furthermore, in the vertical direction, due to the simple adhesive method, the tiles may loosen due to weak adhesion or vibration. Summary of the Invention

[0004] The purpose of this invention is to provide a three-dimensional ceramic tile adhesive and its manufacturing process to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] A type of 3D tile adhesive, including

[0007] The tile body has T-shaped grooves on the lower surfaces of all four sides, I-shaped blocks are installed inside the T-shaped grooves, and a locking mechanism is installed between the T-shaped grooves and the I-shaped blocks.

[0008] The tile body consists of a substrate layer, a three-dimensional effect layer, a damping layer, an adhesive layer, a release layer, and a surface protective layer;

[0009] The 3D effect layer is disposed on one end face of the substrate layer. A surface protective layer is disposed on the outside of the 3D effect layer. A damping layer is disposed on the side of the substrate layer away from the 3D effect layer. An adhesive layer is disposed on the outside of the damping layer. A release layer is disposed on the outside of the adhesive layer.

[0010] In this invention, the locking mechanism includes a first movable groove and a second movable groove. The first movable groove is vertically arranged in the middle of the I-beam block, and the second movable groove is horizontally arranged in the middle of both sides of the I-beam block. The second movable groove is connected to the first movable groove.

[0011] In this invention, the locking mechanism further includes a pressure rod and a positioning rod. The pressure rod is movably installed inside the first movable groove, and the positioning rod is movably installed inside the second movable groove. The end of the positioning rod near the pressure rod is an inclined surface, and a positioning groove is provided in the middle of the inner side of the T-shaped groove.

[0012] In this invention, both sides of the bottom end of the pressure rod and the movable groove are provided with fixing blocks, and a spring is provided between the fixing blocks.

[0013] In this invention, the substrate layer is made of ceramic, and the thickness of the substrate layer is 8 to 10 mm.

[0014] In this invention, the material of the three-dimensional effect layer is resin, and the thickness of the three-dimensional effect layer is 3-5 mm.

[0015] In this invention, the damping layer is made of cork, and the thickness of the damping layer is 4-6 mm.

[0016] In this invention, the adhesive layer is made of acrylic pressure-sensitive adhesive, and the thickness of the adhesive layer is 0.3-0.5 mm.

[0017] In this invention, the surface protective layer is made of polyurethane transparent protective paint, and the thickness of the surface protective layer is 0.1-0.2 mm.

[0018] A manufacturing process for three-dimensional ceramic tile installation includes the following steps:

[0019] Step 1: Use at least one of the following ceramic raw materials: kaolin, feldspar, and quartz. Mix them in proportion and grind them into uniform particles. Add water to make ceramic slurry. Use a mold to dry press the ceramic slurry into a sheet structure with a thickness of 8-10 mm. Place the formed ceramic substrate layer into a kiln and sinter it at 1000-1300℃. Cool it after sintering.

[0020] Step 2: Add pigments or fillers to epoxy resin or unsaturated polyester resin and mix thoroughly. Apply the prepared resin to one side of the ceramic substrate layer with a thickness of 3-5mm. Apply the resin using a scraper or spraying method and create a three-dimensional effect through a mold or multiple layers. Place the resin-coated tile under the appropriate temperature and light conditions for the type of resin to cure.

[0021] Step 3: Select cork raw materials, clean and dry them, cut them into blocks, process the cork blocks into thin slices with a thickness of 4-6mm, and use cork adhesive to stick them onto the ceramic substrate layer on the side away from the 3D effect layer;

[0022] Step 4: Mix acrylate monomers, initiators, tackifiers, and crosslinking agents in proportion, and carry out polymerization reaction at a specific temperature and stirring speed to prepare acrylate pressure-sensitive adhesive. Use a coating machine to uniformly coat the acrylate pressure-sensitive adhesive on the outside of the damping layer with a coating thickness of 0.3-0.5 mm.

[0023] Step 5: Apply the release paper or release film to the surface coated with the adhesive layer, ensuring there are no bubbles or wrinkles.

[0024] Step 6: Prepare the polyurethane transparent protective varnish as required, and add leveling agent or defoamer. Apply the protective varnish to the outside of the three-dimensional effect layer by spraying, brushing or rolling, with a coating thickness of 0.1 to 0.2 mm, and then dry or cure.

[0025] Compared with the prior art, the beneficial effects of the present invention are:

[0026] 1. This invention adopts a mortise and tenon joint method. By opening T-shaped grooves on the lower end face of the four sides of the tile body and setting I-shaped blocks with locking mechanisms, the I-shaped blocks are inserted into the T-shaped grooves and automatically locked by the locking mechanism during splicing. This structure ensures that the tile body will not shift in the horizontal or vertical position after splicing. Compared with traditional adhesive or simple splicing methods, it greatly improves the structural stability after laying. For example, in the laying of floor tiles, even if subjected to external forces such as people walking or furniture moving, the connection between the tiles remains stable and will not loosen or shift.

[0027] 2. The damping layer of the present invention is made of cork with a thickness of 4-6mm. Cork can absorb and disperse vibration energy, solving the problem that existing tile stickers are easily damaged in vibration environments. For example, in a home environment, if an object accidentally hits the tile sticker, the damping layer 6 can reduce the impact force on the internal structure of the tile sticker, and at the same time, it can also reduce noise for the residents on the lower floor. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the overall structure of a three-dimensional ceramic tile adhesive according to the present invention;

[0029] Figure 2 This is a schematic diagram of the installation of a pressure rod for a three-dimensional ceramic tile according to the present invention;

[0030] Figure 3 This is a schematic diagram of the damping layer structure of a three-dimensional ceramic tile according to the present invention;

[0031] Figure 4 This invention provides a three-dimensional ceramic tile adhesive. Figure 1 An enlarged view of point A in the diagram;

[0032] Figure 5 This invention provides a three-dimensional ceramic tile adhesive.Figure 2 An enlarged diagram of point B in the diagram.

[0033] In the diagram: 1. Tile body; 2. T-slot; 3. I-beam; 4. Substrate layer; 5. 3D effect layer; 6. Damping layer; 7. Adhesive layer; 8. Release layer; 9. Surface protective layer; 10. Movable groove one; 11. Movable groove two; 12. Pressure rod; 13. Positioning rod; 14. Positioning groove; 15. Fixing block; 16. Spring. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] like Figures 1-5 As shown, the present invention provides a technical solution:

[0036] A three-dimensional tile adhesive includes a tile adhesive body 1. T-slots 2 are formed on the lower surfaces of all four sides of the tile adhesive body 1. I-shaped blocks 3 are arranged inside the T-slots 2. A locking mechanism is provided between the T-slots 2 and the I-shaped blocks 3. The locking mechanism includes a movable groove 10 and a movable groove 2 11. The movable groove 10 is vertically arranged in the middle of the I-shaped block 3. The movable groove 2 11 is horizontally arranged in the middle of both sides of the I-shaped block 3. The movable groove 2 11 is connected to the movable groove 10. The locking mechanism also includes a pressure rod 12 and a positioning rod 13. The pressure rod 12 is movably installed inside the movable groove 10. The positioning rod 13 is movably installed inside the movable groove 2 11. The end of the positioning rod 13 near the pressure rod 12 is inclined. A positioning groove 14 is provided in the middle of the inner side of the T-slot 2. Fixing blocks 15 are provided on both sides of the bottom end of the pressure rod 12 and the movable groove 10. A spring 16 is provided between the fixing blocks 15.

[0037] In this embodiment, multiple tiles can be assembled during installation. During assembly, the two ends of the I-shaped block 3 are respectively engaged in the T-shaped groove 2 on the outer side of the two tile body 1. When laying the tile body 1, the three-dimensional effect layer 5 faces upward. When placing the I-shaped block 3, the pressure rod 12 and the three-dimensional effect layer 5 need to be aligned in the same direction. When engaging, the end face of the T-shaped groove 2 presses down on the pressure rod 12. After being pressed, the pressure rod 12 descends and drives the positioning rods 13 on both sides to extend outward until the outer end of the positioning rod 13 is engaged in the positioning groove 14 and locked. This achieves a tenon and mortise connection. The tile body 1 after assembly will not shift in the horizontal or vertical position, thereby improving the structural stability after installation.

[0038] like Figure 3As shown, the tile body 1 consists of a substrate layer 4, a three-dimensional effect layer 5, a damping layer 6, an adhesive layer 7, a release layer 8, and a surface protective layer 9. The three-dimensional effect layer 5 is disposed on one end face of the substrate layer 4. The surface protective layer 9 is disposed on the outer side of the three-dimensional effect layer 5. The damping layer 6 is disposed on the side of the substrate layer 4 away from the three-dimensional effect layer 5. The adhesive layer 7 is disposed on the outer side of the damping layer 6. The release layer 8 is disposed on the outer side of the adhesive layer 7. The substrate layer 4 is made of ceramic and has a thickness of 8-10 mm. The three-dimensional effect layer 5 is made of resin and has a thickness of 3-5 mm. The damping layer 6 is made of cork and has a thickness of 4-6 mm. The adhesive layer 7 is made of acrylic pressure-sensitive adhesive and has a thickness of 0.3-0.5 mm. The surface protective layer 9 is made of polyurethane transparent protective varnish and has a thickness of 0.1-0.2 mm.

[0039] In this embodiment, the device consists of a multi-layer structure composed of a substrate layer 4, a three-dimensional effect layer 5, a damping layer 6, an adhesive layer 7, a release layer 8, and a surface protective layer 9. The layers work together to improve the overall stability of the tile adhesive.

[0040] The substrate layer 4 serves as the basic structure, providing fundamental support strength for the entire tile installation. The ceramic substrate layer 4 has high hardness and wear resistance, enabling it to withstand certain external impacts and daily wear.

[0041] The 3D effect layer 5 is set on one side of the substrate layer 4, which not only increases the aesthetics of the tile but also bonds tightly with the substrate layer 4. To a certain extent, it shares the pressure applied to the surface of the tile. The resin material 3D effect layer 5 has a certain degree of flexibility, which can buffer some of the impact force and reduce the possibility of deformation or damage to the tile caused by external force.

[0042] The damping layer 6 is located on the other side of the substrate layer 4. Made of cork, the damping layer 6 has excellent shock absorption and cushioning properties. When the tile is subjected to vibration or minor impact, the damping layer 6 can absorb and disperse energy, further protecting the overall structure of the tile. For example, in a home environment, if an object accidentally hits the tile, the damping layer 6 can reduce the impact force on the internal structure of the tile, while also reducing noise for residents on lower floors.

[0043] The adhesive layer 7 ensures that the tile adhesive can be firmly adhered to the target surface. The acrylic pressure-sensitive adhesive layer 7 has good adhesion and can adapt to different adhesive surfaces, ensuring that the tile adhesive will not easily fall off during use.

[0044] Release layer 8 protects adhesive layer 7 before the tile adhesive is used, preventing adhesive layer 7 from being contaminated or prematurely bonded, and ensuring that adhesive layer 7 can achieve the best bonding effect during the bonding process.

[0045] The surface protective layer 9 provides additional protection for the three-dimensional effect layer 5. The surface protective layer 9, made of polyurethane transparent protective varnish, can prevent the three-dimensional effect layer 5 from being scratched, stained, or corroded, thus extending the service life of the tile and maintaining its aesthetics.

[0046] A manufacturing process for three-dimensional ceramic tile installation includes the following steps:

[0047] Step 1: Use at least one of the following ceramic raw materials: kaolin, feldspar, and quartz. Mix them in proportion and grind them into uniform particles. Add water to make ceramic slurry. Use a mold to dry press the ceramic slurry into a sheet structure with a thickness of 8-10 mm. Place the formed ceramic substrate layer into a kiln and sinter it at 1000-1300℃. Cool it after sintering.

[0048] In this step, the specific proportions of the ceramic raw materials kaolin, feldspar, and quartz are as follows:

[0049] The kaolin content is 20% to 40%. A higher kaolin content can improve the plasticity of ceramics and help with molding, but too high a content may affect the sintering performance and hardness of ceramics.

[0050] Feldspar accounts for 10% to 30%. The main function of feldspar is to lower the sintering temperature. An appropriate amount of feldspar can enable ceramics to achieve better sintering results at a lower temperature.

[0051] Quartz content ranges from 30% to 60%. Quartz can improve the hardness and wear resistance of ceramics. When the quartz content is 40%, the resulting ceramic substrate layer has good hardness and is suitable as a substrate for tile laying.

[0052] Step 2: Add pigments or fillers to epoxy resin or unsaturated polyester resin and mix thoroughly. Apply the prepared resin to one side of the ceramic substrate layer with a thickness of 3-5mm. Apply the resin using a scraper or spraying method and create a three-dimensional effect through a mold or multiple layers. Place the resin-coated tile under the appropriate temperature and light conditions for the type of resin to cure.

[0053] In this step, the specific ratio range of pigment to resin is as follows:

[0054] The pigment content is 1% to 10% (relative to the weight of the resin). If the pigment content is less than 1%, the desired color effect cannot be achieved, while more than 10% will affect the performance of the resin, such as reducing the resin's transparency or flexibility. When making a three-dimensional effect layer with a certain color depth, a pigment content of 5% can ensure the color effect without excessively affecting the resin's curing and other properties.

[0055] Step 3: Select cork raw materials, clean and dry them, cut them into blocks, process the cork blocks into thin slices with a thickness of 4-6mm, and use cork adhesive to stick them onto the ceramic substrate layer on the side away from the 3D effect layer;

[0056] Step 4: Mix acrylate monomers, initiators, tackifiers, and crosslinking agents in proportion, and carry out polymerization reaction at a specific temperature and stirring speed to prepare acrylate pressure-sensitive adhesive. Use a coating machine to uniformly coat the acrylate pressure-sensitive adhesive on the outside of the damping layer with a coating thickness of 0.3-0.5 mm.

[0057] In this step, the specific ratio ranges of acrylate monomers, initiators, tackifiers, and crosslinking agents are as follows:

[0058] Acrylic monomers, comprising 70%–90%, are the main component of pressure-sensitive adhesives (PSAs). A higher content ensures the basic tack and overall properties after polymerization. When the acrylate monomer content is 80%, it provides better initial tack and holding power.

[0059] The initiator concentration is 0.1% to 1%. The initiator is used to initiate the polymerization reaction; too little will lead to incomplete polymerization, while too much will cause the reaction to be too vigorous. When the initiator content is 0.5%, the acrylate monomers can be fully polymerized at a suitable reaction rate.

[0060] The tackifier content is 5% to 15%. The tackifier can improve the adhesion of the pressure-sensitive adhesive. When the tackifier content is 10%, it can significantly enhance the adhesion ability of the pressure-sensitive adhesive to different surfaces.

[0061] The crosslinking agent is 0.5% to 3%. The crosslinking agent is used to enhance the cohesion of the pressure-sensitive adhesive and prevent the adhesive layer from flowing or losing its tack during use. When the crosslinking agent content is 1.5%, it can improve the cohesive strength of the pressure-sensitive adhesive while ensuring its flexibility.

[0062] Step 5: Apply the release paper or release film to the surface coated with the adhesive layer, ensuring there are no bubbles or wrinkles.

[0063] Step 6: Prepare the polyurethane transparent protective varnish as required, and add leveling agent or defoamer. Apply the protective varnish to the outside of the three-dimensional effect layer by spraying, brushing or rolling, with a coating thickness of 0.1 to 0.2 mm, and then dry or cure.

[0064] In this step, the leveling agent is 0.1% to 1% (relative to the weight of the protective varnish). The leveling agent is mainly used to improve the coating performance of the protective varnish, so that it forms a smoother film on the surface. When the leveling agent ratio is 0.5%, it can effectively reduce the orange peel phenomenon on the surface and improve the smoothness of the surface when applying polyurethane transparent protective varnish.

[0065] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0066] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A three-dimensional ceramic tile, characterized in that: include The tile body (1) has T-shaped grooves (2) on the lower surface of all four sides, and I-shaped blocks (3) are provided inside the T-shaped grooves (2). A locking mechanism is provided between the T-shaped grooves (2) and the I-shaped blocks (3). The tile body (1) is composed of a substrate layer (4), a three-dimensional effect layer (5), a damping layer (6), an adhesive layer (7), a release layer (8), and a surface protective layer (9); The three-dimensional effect layer (5) is disposed on one side end face of the substrate layer (4). A surface protective layer (9) is disposed on the outside of the three-dimensional effect layer (5). A damping layer (6) is disposed on the side of the substrate layer (4) away from the three-dimensional effect layer (5). An adhesive layer (7) is disposed on the outside of the damping layer (6). A release layer (8) is disposed on the outside of the adhesive layer (7).

2. The three-dimensional tile adhesive according to claim 1, characterized in that: The locking mechanism includes a first movable groove (10) and a second movable groove (11). The first movable groove (10) is vertically arranged in the middle of the I-shaped block (3), and the second movable groove (11) is horizontally arranged in the middle of both sides of the I-shaped block (3). The second movable groove (11) is connected to the first movable groove (10).

3. The three-dimensional tile adhesive according to claim 1, characterized in that: The locking mechanism also includes a pressure rod (12) and a positioning rod (13). The pressure rod (12) is movably installed inside the first movable groove (10), and the positioning rod (13) is movably installed inside the second movable groove (11). The end of the positioning rod (13) near the pressure rod (12) is inclined, and a positioning groove (14) is provided in the middle of the inner side of the T-shaped groove (2).

4. A three-dimensional tile adhesive according to claim 1, characterized in that: The pressure rod (12) and the bottom of the movable groove (10) are both provided with fixing blocks (15), and a spring (16) is provided between the fixing blocks (15).

5. A three-dimensional tile adhesive according to claim 1, characterized in that: The substrate layer (4) is made of ceramic and has a thickness of 8 to 10 mm.

6. A three-dimensional tile adhesive according to claim 1, characterized in that: The material of the three-dimensional effect layer (5) is resin, and the thickness of the three-dimensional effect layer (5) is 3-5mm.

7. A three-dimensional tile adhesive according to claim 1, characterized in that: The damping layer (6) is made of cork and has a thickness of 4-6 mm.

8. A three-dimensional ceramic tile adhesive according to claim 1, characterized in that: The adhesive layer (7) is made of acrylic pressure-sensitive adhesive and has a thickness of 0.3 to 0.5 mm.

9. A three-dimensional ceramic tile adhesive according to claim 1, characterized in that: The surface protective layer (9) is made of polyurethane transparent protective paint, and the thickness of the surface protective layer (9) is 0.1-0.2 mm.

10. The manufacturing process of a three-dimensional ceramic tile according to claim 1, characterized in that: Includes the following steps: Step 1: Use at least one of the following ceramic raw materials: kaolin, feldspar, and quartz. Mix them in proportion and grind them into uniform particles. Add water to make ceramic slurry. Use a mold to dry press the ceramic slurry into a sheet structure with a thickness of 8-10 mm. Place the formed ceramic substrate layer into a kiln and sinter it at 1000-1300℃. Cool it after sintering. Step 2: Add pigments or fillers to epoxy resin or unsaturated polyester resin and mix thoroughly. Apply the prepared resin to one side of the ceramic substrate layer with a thickness of 3-5mm. Apply the resin using a scraper or spraying method and create a three-dimensional effect through a mold or multiple layers. Place the resin-coated tile under the appropriate temperature and light conditions for the type of resin to cure. Step 3: Select cork raw materials, clean and dry them, cut them into blocks, process the cork blocks into thin slices with a thickness of 4-6mm, and use cork adhesive to stick them onto the ceramic substrate layer on the side away from the 3D effect layer; Step 4: Mix acrylate monomers, initiators, tackifiers, and crosslinking agents in proportion, and carry out polymerization reaction at a specific temperature and stirring speed to prepare acrylate pressure-sensitive adhesive. Use a coating machine to uniformly coat the acrylate pressure-sensitive adhesive on the outside of the damping layer with a coating thickness of 0.3-0.5 mm. Step 5: Apply the release paper or release film to the surface coated with the adhesive layer, ensuring there are no bubbles or wrinkles. Step 6: Prepare the polyurethane transparent protective varnish as required, and add leveling agent or defoamer. Apply the protective varnish to the outside of the three-dimensional effect layer by spraying, brushing or rolling, with a coating thickness of 0.1 to 0.2 mm, and then dry or cure.

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