A process and apparatus for spray coating a ceramic substrate surface

Abstract

This invention proposes a process for spraying ceramic substrate surfaces, using a ceramic polymer material formulation as the spraying raw material. The process includes: pre-treatment of raw materials, including collecting the ceramic polymer material formulation, sequentially sieving, adding water and additives for conditioning and stirring, to prepare a homogeneous ceramic polymer material formulation slurry with stable spraying flowability; equipment preparation, including powering on the spraying machine, starting the dust extraction fan, geared motor, and air supply system, and sequentially adjusting the high-pressure air supply pressure, the output flow rate of the electronic flow valve, and the negative pressure value of the dust extraction fan; conveying the substrate; automatic spraying; dust prevention and collection; controlling material spray interruption; and outputting the finished product, including: the ceramic substrate with the bottom surface sprayed is sent out of the spraying equipment from the discharge port by the transmission roller, transferred to a room temperature air drying station for post-drying treatment, and after the sprayed coating has initially cured, it is transferred to the ceramic deep processing process.

Description

Technical Field

[0001] This invention relates to the technical field of spraying equipment and supporting production processes for ceramic substrates, and particularly to a process and equipment for spraying treatment of ceramic substrate surfaces. Specifically, it relates to a process and complete set of equipment that utilizes a formula of ceramic polymer materials as spraying raw materials and uses automated spraying equipment to complete the spraying treatment of the bottom surface of ceramic substrates. Background Technology

[0002] Against the backdrop of the rapid development of the construction industry, ceramic-polymer material formulations are widely used. These formulations consist of two types of components: inorganic ceramic mineral powders (quartz, kaolin, talc, alumina) and organic polymer materials (polyacrylate micron powder, polyurethane emulsion, sodium polyacrylate, CMC polymer additives). The inorganic ceramic powders provide the mineral properties of the coating, while the organic polymers provide bonding, film-forming, and rheological control properties. Together, they form the complete raw material for the spray coating slurry. However, ceramic-polymer material formulations are prone to causing environmental pollution problems and putting pressure on the ecological environment due to solid waste emissions.

[0003] Spraying equipment is a key piece of equipment used to spray various materials such as slurries and paints. It is widely used in ceramics, chemicals, bioengineering, environmental protection, metallurgy, and mining. If spraying equipment can be improved to enable the recycling and reuse of ceramic polymer materials through formulation, it can fundamentally solve the environmental pollution problem of ceramic polymer materials, reduce the pressure of solid waste emissions on the ecological environment, and comply with the national policies of energy conservation, emission reduction, and green development.

[0004] In existing technologies, only single spraying machines exist, and there is no standardized spraying process that is compatible with the raw materials in the formulation of ceramic polymers. This results in several practical limitations in actual production:

[0005] 1. The raw materials of the ceramic inorganic mineral powder in the formulation of ceramic polymer materials contain stones, coarse sand, and plant fiber impurities. The slurry is made directly without screening process, and the impurities are very likely to clog the nozzle pipeline, solenoid valve, and electronic flow valve, resulting in a high frequency of equipment failure.

[0006] 2. The ceramic polymer materials have no fixed conditioning ratio in their composition formula, resulting in an imbalance between the solid and liquid ratios of the slurry. If the slurry has poor fluidity, it will cause spraying interruption. If the fluidity is too high, it will cause the slurry to flow on the substrate surface and the coating thickness to be uneven.

[0007] 3. Without fixed conveyor speed control, if the substrate is conveyed too fast, the coating will not be fully covered; if the substrate is conveyed too slowly, the slurry will accumulate in some areas, resulting in poor coating consistency of the finished product.

[0008] 4. There is no standardized adjustment range for the distance between the nozzle and the bottom surface of the substrate. If the distance is too small, the nozzle is prone to scratching the ceramic substrate. If the distance is too large, the spray coverage will be insufficient.

[0009] 5. Without fixed negative pressure dust collection parameters, spray dust cannot be collected stably, and dust continues to overflow and pollute the workshop;

[0010] 6. Without a post-coating curing process, the wet ceramic polymer materials are directly transferred to the next process after being sprayed, which easily leads to coating wear and peeling, increasing the number of defective products.

[0011] The earlier application 202511283675.6 (CN121082477A) only disclosed the mechanical structure of the equipment, without disclosing any supporting process steps or process parameters. The equipment alone cannot achieve stable, standardized, and resource-based spraying production of ceramic polymer materials, and the technical solution is not complete enough. Summary of the Invention

[0012] This invention proposes a process and equipment for spray coating treatment of ceramic substrates, which improves upon traditional equipment in terms of environmental friendliness, efficient assembly line production, and intelligent monitoring and control. The technical problems this invention aims to solve include:

[0013] 1. The entire mechanical structure of the spraying machine is fully inherited from the prior patent, satisfying the priority requirements, including all parts, assembly relationships, transmission structure, dustproof structure, and electrical control structure of the equipment.

[0014] 2. Provide a standardized process for spraying ceramic polymer materials that are perfectly matched with the equipment, thereby making up for the deficiencies of prior patents in that they lack process solutions and process parameter control.

[0015] 3. Solve the production problem of impurities in the raw materials of ceramic polymer materials clogging the spraying pipes and nozzles;

[0016] 4. Solve the problems of uneven coating thickness, slurry flow, and incomplete coating coverage on ceramic substrates caused by the lack of standardized process parameters;

[0017] 5. Achieve closed-loop negative pressure centralized collection of spraying dust to control dust overflow;

[0018] 6. Relying on photoelectric sensors to control the start and stop of spraying eliminates the waste of spraying slurry during periods without substrate;

[0019] 7. Establish a resource-based circular production process for the mutual composition formula of ceramic polymer materials, which is adapted to continuous production line spraying operations on ceramic substrates.

[0020] This invention provides a method for spraying a ceramic substrate surface, using a ceramic polymer material composition formula as the spraying raw material, comprising:

[0021] S1, Pre-treatment raw materials, including: collecting the ceramic polymer material composition formula, sequentially completing sieving, adding water and additives for conditioning and stirring, to prepare a homogeneous ceramic polymer material composition formula slurry with stable spray flowability; wherein, the ceramic polymer material composition formula includes a basic solid phase matrix and a liquid phase conditioning system as modifying additives, wherein the solid phase matrix of the basic solid phase matrix, after being sieved through an 80-120 mesh vibrating sieve, has a total mass of 100 parts, including 62 parts of quartz fine powder, 21 parts of kaolin ultrafine powder, 9 parts of talc micro powder, 5 parts of alumina ultrafine powder, and 3 parts of polymer modified powder; wherein, the quartz fine powder is silicon dioxide with a particle size of 100-180 μm; the kaolin ultrafine powder is layered aluminosilicate clay mineral; the polymer modified powder is 120 mesh polyacrylic acid. Ester micro powder; the liquid-phase blending system is matched with the basic solid phase matrix at 100 parts solid powder, corresponding to a solid-liquid mass ratio in the range of 1:1.2 to 1:1.8; the liquid phase component of the liquid-phase blending system includes 110-165 parts by mass of industrial deionized water and 10-15 parts by mass of water-based polymeric additives, wherein the industrial deionized water is the dispersion medium; the water-based polymeric additives are liquid compound type, including: 40wt% sodium polyacrylate dispersant, 35wt% water-based polyurethane emulsion, 15wt% silicone defoamer, and 10wt% carboxymethyl cellulose thickener; the process parameters of the conditioning and stirring include: stirring speed 400 r / min, stirring time 15 min, and standing for defoaming for 5 min after stirring to form a homogeneous ceramic polymeric material formulation slurry.

[0022] S2, Prepare the equipment, including: Powering on the entire spraying machine, starting the dust extraction fan, geared motor and air supply system, and adjusting the high-pressure air supply pressure, the output flow of the electronic flow valve and the negative pressure value of the dust extraction fan in sequence.

[0023] S3, conveying the substrate, including: placing the ceramic substrate to be sprayed from the dustproof upper cabinet inlet onto the surface of the transmission rollers, the geared motor driving all the transmission rollers to rotate synchronously through the chain, and the ceramic substrate passing through the spraying cavity at a uniform speed along the conveying direction;

[0024] S4, automatic spraying is performed, including: after the photoelectric sensor at the feed inlet detects that the ceramic substrate has entered the cavity, it transmits a material presence signal to the control host; the control host issues an opening command, the solenoid valve is turned on and the electronic flow valve is opened, and the high-pressure slurry in the feed tank is transported to each nozzle along the high-pressure feed pipe; the nozzle sprays the slurry upward through the gap of the transmission roller to complete the spraying of the lower surface of the ceramic substrate in the moving state; according to the thickness specification of the ceramic substrate, the vertical height of the nozzle mounting plate is adjusted in advance by the height adjustment bracket to limit the distance between the nozzle and the bottom surface of the substrate.

[0025] S5, dust prevention and collection, including: the dust extraction fan keeps running continuously throughout the spraying process, the dust-proof upper cabinet and the dust-proof lower cabinet together form a closed spraying cavity, and the mist slurry dust and dry fine powder generated during spraying are continuously extracted and collected by negative pressure through the dust extraction port and dust extraction pipe of the cabinet.

[0026] S6, controlling material spray interruption, including: when the photoelectric sensor at the discharge port detects that no ceramic substrate is passing on the conveyor line, it transmits a no-material signal to the control host; the control host issues a shutdown command, the solenoid valve cuts off the slurry conveying pipeline, and all nozzles stop spraying synchronously.

[0027] S7, Output the finished product, including: the ceramic substrate with the bottom surface sprayed is sent out of the spraying equipment from the discharge port by the transmission roller, and transferred to the room temperature air drying station for air drying post-treatment. After the sprayed coating is initially cured, it is transferred to the ceramic deep processing process.

[0028] Preferably, the sieving in S1 includes: using a vibrating sieving device to grade and filter the original ceramic polymer materials according to their composition, with a screen mesh size of 80-120 mesh, to remove stones, coarse sand, and coarse fibers, and to obtain fine powder.

[0029] Preferably, the conditioning and stirring in S1 includes: adding water and ceramic binder to the sieved powder, with a solid-liquid mass ratio of 1:1.2 to 1:1.8, a stirring speed of 300 to 500 r / min, and a stirring time of 10 to 20 min.

[0030] Preferably, in step S4, the high-pressure slurry in the feed tank is transported to each nozzle along the high-pressure feed pipe, which includes: the high-pressure air inlet pipe of the feed tank providing a constant air supply pressure of 0.2 to 0.5 MPa.

[0031] Preferably, the process of the nozzle spraying slurry upward through the gap between the drive rollers includes: the drive rollers providing a conveying linear speed of 0.3 to 0.8 m / min, and the ceramic substrate to be coated passing through at a uniform speed.

[0032] Preferably, the step of adjusting the vertical height of the nozzle mounting plate in advance using the height adjustment bracket to limit the distance between the nozzle and the bottom surface of the substrate includes: loosening the adjusting bolts, moving the angle iron and the nozzle mounting plate along the vertical slide groove of the vertical plate, controlling the distance between the nozzle and the bottom surface of the substrate to 5-15mm, and tightening the locking bolts for positioning after adjustment.

[0033] Preferably, the process of spraying the lower surface of the ceramic substrate in a moving state includes: independently controlling the output flow rate of the slurry from a single nozzle to 150-300 mL / min based on an electronic flow valve.

[0034] Preferably, the cabinet dust suction port forms a negative pressure for dust suction, and the negative pressure of the cabinet dust suction port is stable at -300 to -100 Pa, continuously extracting dust from the sealed cavity.

[0035] Preferably, the photoelectric sensor in S6 collects the presence or absence of electrical signals of the material in real time and transmits them to the control host. The host then controls the opening and closing of the solenoid valve, the start and stop of the reduction motor, and the automatic switching between spraying and stopping.

[0036] Preferably, the post-drying process includes: after the substrate is discharged, it is naturally air-dried at room temperature for 8-15 minutes, and the sprayed coating is initially cured.

[0037] The beneficial effects of this invention are:

[0038] This invention uses a ceramic polymer material formulation as the spraying raw material, forming an integrated solution based on complete equipment and standardized processes. The equipment employs a fully enclosed dustproof cabinet with negative pressure dust extraction to reduce dust spillage; the nozzle height is adjustable to accommodate various substrate sizes, and photoelectric sensing enables automatic spray cut-off when no substrate is available, reducing raw material loss. Standardized parameters for screening, conditioning, conveying, spraying, and drying prevent production problems such as slurry blockage and uneven coating thickness. The entire process and equipment achieve resource utilization of the composite formulation slurry, automated production line operation reduces manual intervention, and standardized process parameters at each stage ensure stable finished product quality, combining practicality with environmental friendliness. Attached Figure Description

[0039] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0040] Figure 1 This is a flowchart of the ceramic substrate surface spraying treatment process of the present invention; Figure 2 This is a schematic diagram of the structure of the present invention; Figure 3 This is a side view of the structure of the present invention; Figure 4 This is a connection diagram of the vertical plate, angle iron, and nozzle mounting plate in this invention.

[0043] The reference numerals in the diagram are as follows: 1-Frame, 2-Drive roller, 3-Drive motor, 4-Nozzle mounting plate, 5-Nozzle, 6-Height adjustment frame, 7-High-pressure feed pipe, 8-Control valve, 9-Flow valve, 10-Dustproof upper cabinet, 11-Dustproof lower cabinet, 12-Dust suction port, 13-Feed inlet, 14-Sensor, 15-Vertical plate, 16-Support plate, 17-Adjusting slide, 18-Angle iron, 19-Screw hole, 20-Feeding bucket, 21-Control host. Detailed Implementation

[0044] 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.

[0045] Reference Figure 1 A method for spraying a ceramic substrate surface, using a ceramic polymer material formulation as the spraying raw material, comprising:

[0046] S1, Pre-treatment raw materials, including: collecting the ceramic polymer material composition formula, sequentially completing sieving, adding water and additives for conditioning and stirring, to prepare a homogeneous ceramic polymer material composition formula slurry with stable spray flowability; wherein, the ceramic polymer material composition formula includes a basic solid phase matrix and a liquid phase conditioning system as modifying additives, wherein the solid phase powder of the basic solid phase matrix is ​​100 parts by total mass after being sieved by 80-120 mesh vibration sieve, including 62 parts of quartz fine powder, 21 parts of kaolin ultrafine powder, 9 parts of talc micro powder, 5 parts of alumina ultrafine powder and 3 parts of polymer modified powder.

[0047] In this embodiment, the quartz fine powder is silicon dioxide with a particle size of 100-180 μm; it is derived from ultrafine tailings powder from water-washed sand and gravel processing, serving as a core mineral component in the ceramic polymer material formulation, providing a support framework for the spray coating, and improving the coating's wear resistance and adhesion; the kaolin ultrafine powder is a layered aluminosilicate clay mineral, used to improve the suspension stability of the slurry and prevent rapid solid-phase sedimentation during the spraying process; the talc micro powder is used to improve the lubrication and fluidity of the slurry, reduce wear on the nozzle pipeline, and lower the probability of pipe blockage; the alumina ultrafine powder is used to improve the hardness and water resistance of the spray coating, adapting it to high-temperature subsequent processing of the ceramic substrate; the polymer modified powder is 120-mesh polyacrylate micro powder.

[0048] The polymer component of the basic solid phase is a powdered polymer that swells in water to form an adhesive film, replacing traditional cement and resin adhesives to achieve a "ceramic mineral + polymer" composite system.

[0049] The liquid-phase blending system is matched with the basic solid phase matrix at 100 parts of solid powder, corresponding to a solid-liquid mass ratio in the range of 1:1.2 to 1:1.8. Based on 100 parts by mass of the solid powder, the total amount of liquid added is 120 to 180 parts by mass. The liquid phase component of the liquid-phase blending system includes 110 to 165 parts by mass of industrial deionized water and 10 to 15 parts by mass of water-based polymeric additives. The industrial deionized water serves as a dispersion medium to prevent calcium and magnesium from being absorbed by tap water. Ions cause slurry flocculation and agglomeration; the water-based polymeric additive is a liquid compound type, including: sodium polyacrylate dispersant 40wt%, used to reduce powder agglomeration and improve slurry homogeneity; water-based polyurethane emulsion 35wt%, a film-forming polymer, used to improve the adhesion between the coating and the ceramic substrate; silicone defoamer 15wt%, used to eliminate bubbles generated by stirring and high-pressure conveying, and prevent spray pinholes; carboxymethyl cellulose thickener 10wt%, used to adjust slurry viscosity and control spray flowability.

[0050] In this embodiment, the standard production ratio adopts the intermediate value of the process embodiment, that is, the solid-liquid ratio is 1:1.5. The total solid dry material is 100kg, including 62kg of quartz fine powder, 21kg of kaolin, 9kg of talc, 5kg of alumina and 3kg of polyacrylate micro powder; the total liquid addition is 150kg, including 137kg of deionized water and 13kg of compound polymer additives.

[0051] The process parameters for conditioning and stirring include: stirring speed of 400 r / min, stirring time of 15 min, and standing for 5 min after stirring to defoam, forming a homogeneous ceramic polymer material slurry.

[0052] In this embodiment, the corresponding description of the ceramic polymer material composition formula adapted to the process of the present invention is provided.

[0053] (1) Screening matching: After all solid dry materials are mixed, they are screened using a 100-mesh vibrating screen to remove lumps and hard coarse particles, corresponding to the 80-120 mesh screening process, to prevent blockage of pipelines, solenoid valves and electronic flow valves.

[0054] (2) Conditioning parameters matching: solid-liquid mass ratio 1:1.5, slurry viscosity stable, no material breakage or flow defects;

[0055] (3) High pressure transport compatibility: The polymeric dispersants and thickeners in the formula can withstand high pressure gas supply of 0.2 to 0.5 MPa without solid phase stratification and precipitation;

[0056] (4) Spraying and molding adaptation: Under the conditions of single nozzle flow rate of 150-300mL / min and nozzle spacing of 5-15mm, the polymer film-forming component quickly forms a uniform and continuous coating on the bottom surface of the ceramic substrate, and can be initially cured and formed after air drying for 8-15min.

[0057] (5) Dust control adaptation: The polymer components in the formula can reduce the amount of dry dust scattered during spraying. Combined with negative pressure dust collection of -300 to -100Pa, the dust concentration in the workshop is significantly reduced.

[0058] Based on the formulation that adapts to different ceramic substrates and adjusts the composition of ceramic polymer materials, the adjustable range includes:

[0059] (1) Thin coating substrate (thin plate ceramic, nozzle spacing 5-8mm): the solid-liquid ratio is reduced to 1:1.2, the liquid phase additive is reduced to 10 parts, the slurry viscosity is low, and a thin coating is sprayed.

[0060] (2) Thick coating substrate (thick brick, whole ceramic plate, nozzle spacing 12-15mm): the solid-liquid ratio is increased to 1:1.8, the liquid phase additive is increased to 15 parts, the slurry viscosity is increased, and the coating thickness is increased.

[0061] (3) High wear-resistant substrate: The proportion of alumina ultrafine powder is increased to 8 parts, corresponding to a reduction of 3 parts of quartz fine powder;

[0062] (4) High bonding requirement substrate: polyacrylate micro powder is increased to 5 parts, and talc micro powder is reduced by 2 parts.

[0063] S2, Prepare the equipment, including: Powering on the entire spraying machine, starting the dust extraction fan, geared motor and air supply system, and adjusting the high-pressure air supply pressure, the output flow of the electronic flow valve and the negative pressure value of the dust extraction fan in sequence.

[0064] S3, conveying the substrate, including: placing the ceramic substrate to be sprayed from the dustproof upper cabinet inlet onto the surface of the transmission rollers, the geared motor driving all the transmission rollers to rotate synchronously through the chain, and the ceramic substrate passing through the spraying cavity at a uniform speed along the conveying direction;

[0065] S4, automatic spraying is performed, including: after the photoelectric sensor at the feed inlet detects that the ceramic substrate has entered the cavity, it transmits a material presence signal to the control host; the control host issues an opening command, the solenoid valve is turned on and the electronic flow valve is opened, and the high-pressure slurry in the feed tank is transported to each nozzle along the high-pressure feed pipe; the nozzle sprays the slurry upward through the gap of the transmission roller to complete the spraying of the lower surface of the ceramic substrate in the moving state; according to the thickness specification of the ceramic substrate, the vertical height of the nozzle mounting plate is adjusted in advance by the height adjustment bracket to limit the distance between the nozzle and the bottom surface of the substrate.

[0066] S5, dust prevention and collection, including: the dust extraction fan keeps running continuously throughout the spraying process, the dust-proof upper cabinet and the dust-proof lower cabinet together form a closed spraying cavity, and the mist slurry dust and dry fine powder generated during spraying are continuously extracted and collected by negative pressure through the dust extraction port and dust extraction pipe of the cabinet.

[0067] S6, controlling material spray interruption, including: when the photoelectric sensor at the discharge port detects that no ceramic substrate is passing on the conveyor line, it transmits a no-material signal to the control host; the control host issues a shutdown command, the solenoid valve cuts off the slurry conveying pipeline, and all nozzles stop spraying synchronously.

[0068] S7, Output the finished product, including: the ceramic substrate with the bottom surface sprayed is sent out of the spraying equipment from the discharge port by the transmission roller, and transferred to the room temperature air drying station for air drying post-treatment. After the sprayed coating is initially cured, it is transferred to the ceramic deep processing process.

[0069] In a preferred embodiment, the sieving in S1 includes: using a vibrating sieving device to grade and filter the original ceramic polymer materials according to their composition, with a screen mesh size of 80-120 mesh, to remove stones, coarse sand, and coarse fibers, thereby obtaining fine powder and eliminating the source of pipeline blockage.

[0070] In a preferred embodiment, the conditioning and stirring in S1 includes: adding water and ceramic binder to the sieved powder, with a solid-liquid mass ratio of 1:1.2 to 1:1.8, a stirring speed of 300 to 500 r / min, a stirring time of 10 to 20 min, and the slurry being homogeneous and free of lumps.

[0071] In a preferred embodiment, the high-pressure slurry in the feed tank of step S4 is transported to each nozzle along the high-pressure feed pipe, including: the high-pressure air inlet pipe of the feed tank provides an air supply pressure of 0.2 to 0.5 MPa, and the constant air pressure ensures continuous and stable slurry delivery without interruption or pulsed discharge.

[0072] In a preferred embodiment, the nozzle sprays slurry upward through the gap between the drive rollers, wherein the drive rollers provide a conveying linear speed of 0.3 to 0.8 m / min, the ceramic substrate to be coated passes through at a uniform speed, and the coating is uniformly covered.

[0073] As a preferred embodiment, the step of adjusting the vertical height of the nozzle mounting plate in advance by means of the height adjustment bracket to limit the distance between the nozzle and the bottom surface of the substrate includes: loosening the adjusting bolts, moving the angle iron and the nozzle mounting plate along the vertical slide groove of the vertical plate, controlling the distance between the nozzle and the bottom surface of the substrate to be 5-15mm, and locking the bolts for positioning after adjustment.

[0074] As a preferred embodiment, the process of spraying the lower surface of the ceramic substrate in a moving state includes: independently controlling the output flow rate of the slurry from a single nozzle to 150-300 mL / min based on an electronic flow valve, and ensuring uniform coating thickness.

[0075] In a preferred embodiment, the cabinet dust suction port forms a negative pressure for dust suction, and the negative pressure of the cabinet dust suction port is stable at -300 to -100 Pa, so that dust inside the sealed cavity is continuously extracted without dust overflow.

[0076] In a preferred embodiment, the photoelectric sensor in step S6 collects the presence or absence of electrical signals of the material in real time and transmits them to the control host. The host then controls the opening and closing of the solenoid valve, the start and stop of the geared motor, and the automatic switching between spraying and stopping spraying.

[0077] As a preferred embodiment, the post-drying process includes: after the substrate is discharged, it is naturally air-dried at room temperature for 8 to 15 minutes, during which the sprayed coating is initially cured, reducing the probability of wear and tear during transportation.

[0078] Reference Figure 2-4 A high-efficiency high-pressure atomizing spraying device includes a frame 1, a conveying device, an adjustable spraying device, a material supply control device, and a dustproof device. The conveying device is horizontally mounted on the frame 1 and includes several horizontally spaced transmission rollers 2. One end of each transmission roller 2 is fixedly mounted with a transmission gear, and the transmission gears are connected by a chain. One end of each transmission roller 2 is connected to a drive motor 3. The adjustable spraying device is installed below the conveying device and includes several nozzle mounting plates 4. The nozzle mounting plates 4 are located below the gaps between the transmission rollers 2, and several upward-facing nozzles 5 are fixedly mounted on the nozzle mounting plates 4. The nozzle mounting plates 4 are mounted on a height adjustment frame 6 with adjustable height. The degree adjustment frame 6 is installed on the frame 1; the material feeding control device includes a high-pressure feed pipe 7, a control valve 8 and a flow valve 9, and the nozzle 5 is connected to the control valve 8, the flow valve 9 and the high-pressure feed pipe 7 in sequence; the dust prevention device includes a dust prevention upper cabinet 10 and a dust prevention lower cabinet 11, both of which are fixedly installed on the frame 1. The dust prevention upper cabinet 10 is located above the transmission roller 2, and the dust prevention lower cabinet 11 is located below the transmission roller 2. The adjustable spraying device is located inside the dust prevention lower cabinet 11. Both the dust prevention upper cabinet 10 and the dust prevention lower cabinet 11 are provided with dust suction ports 12. The side of the dust prevention upper cabinet 10 is provided with a feed port 13 and a discharge port that cooperate with the conveying device. The feed port 13 and the discharge port are respectively equipped with sensors 14 for detecting materials.

[0079] Preferably, the drive motor 3 is a geared motor, which is connected to one end of a transmission roller 2 via a coupling, and the geared motor is fixed on the frame 1.

[0080] Preferably, the height adjustment frame 6 includes two spaced vertical plates 15, the bottom of which is fixed to a support plate 16, which is fixed to the frame 1. The vertical plates 15 are provided with vertical adjustment grooves 17, and also include an angle iron 18 and an adjustment bolt. A screw hole 19 is provided on one right-angled surface of the angle iron 18, and the adjustment bolt passes through the adjustment groove 17 and connects to the screw hole 19. The other right-angled surface of the angle iron is fixedly connected to the nozzle mounting plate 4.

[0081] Preferably, the sensor 14 is a photoelectric sensor, and the transmitting device and the receiving device are located on both sides of the feed inlet 13 and the discharge outlet, respectively; the flow valve 9 is an electronic flow valve; and the control valve 8 is a solenoid valve.

[0082] Preferably, the suction port 12 is connected to a suction pipe, and the suction pipe is connected to a suction fan.

[0083] Preferably, it also includes a feeding hopper 20, a high-pressure feeding pipe 7 connected to the feeding hopper 20, and the feeding hopper 20 is connected to a high-pressure air inlet pipe.

[0084] Preferably, it also includes a control host 21, which is electrically connected to the drive motor 3, the control valve 8, the flow valve 9 and the sensor 14 respectively.

[0085] This invention features a dustproof upper cabinet 10 and a dustproof lower cabinet 11, providing all-around dust protection. The dust is then uniformly removed using a dust extraction pipe and a dust extraction fan, resulting in good environmental performance, a healthy working environment, and prevention of harm to workers' health.

[0086] Device Application Examples

[0087] A ceramic substrate surface treatment spraying machine includes a frame, a conveying device, an adjustable spraying device, a material supply control device, and a dustproof device. The conveying device is horizontally mounted on the frame and includes several horizontally spaced drive rollers. A drive gear is fixedly mounted at one end of each drive roller, and the drive gears are connected by chains. One end of each drive roller is connected to a drive motor. The adjustable spraying device is installed below the conveying device and includes several nozzle mounting plates located below the gaps between the drive rollers. Several upward-facing nozzles are fixedly mounted on the nozzle mounting plates, and the height of the nozzle mounting plates is adjustable. The nozzle is installed on a height adjustment frame, which is mounted on the machine frame. The feeding control device includes a high-pressure feed pipe, a control valve, and a flow valve. The nozzle is connected to the control valve, the flow valve, and the high-pressure feed pipe in sequence. The dustproof device includes an upper dustproof cabinet and a lower dustproof cabinet, both of which are fixedly installed on the machine frame. The upper dustproof cabinet is located above the drive roller, and the lower dustproof cabinet is located below the drive roller. The adjustable spraying device is located inside the lower dustproof cabinet. Both the upper and lower dustproof cabinets are equipped with dust suction ports. The side of the upper dustproof cabinet has a feed port and a discharge port that cooperate with the conveying device. Sensors for detecting materials are installed at the feed port and the discharge port, respectively.

[0088] The drive motor is a geared motor, which is connected to one end of a transmission roller via a coupling. The geared motor is fixed on the frame.

[0089] The height adjustment frame includes two spaced vertical plates, the bottom of which is fixed to a support plate. The support plate is fixed to the frame. The vertical plates have vertical adjustment grooves. The frame also includes an angle iron and an adjustment bolt. A screw hole is provided on one right-angled surface of the angle iron. The adjustment bolt passes through the adjustment groove and connects to the screw hole. The other right-angled surface of the angle iron is fixedly connected to the nozzle mounting plate.

[0090] The sensor is a photoelectric sensor, the flow valve is an electronic flow valve, and the control valve is a solenoid valve.

[0091] The suction port is connected to a suction pipe, and the suction pipe is connected to a suction fan.

[0092] The equipment also includes a feeding hopper, a high-pressure feed pipe connected to the feeding hopper, and a high-pressure air inlet pipe connected to the feeding hopper.

[0093] The device also includes a control host, which is electrically connected to the drive motor, the control valve, the flow valve and the sensor respectively.

[0094] Detailed explanation of the assembly and connection relationships of each component:

[0095] 1. Frame: The main load-bearing frame of the whole machine is made of welded steel and provides an installation benchmark for the conveying device, dustproof upper and lower cabinets, height adjustment frame and drive motor;

[0096] 2. Conveying device: Multiple drive rollers are arranged in parallel and equidistant, and the drive gears at the ends of all drive rollers are meshed and linked by the same chain to achieve synchronous rotation; each drive roller is coaxially connected to the output shaft of a geared motor, and the geared motor provides the conveying power;

[0097] 3. Adjustable spraying device: The nozzle mounting plate is set below the gap of the transmission rollers, the nozzle is vertically upward, and the slurry is sprayed from bottom to top onto the bottom surface of the ceramic substrate; the nozzle mounting plate is adjusted up and down by means of angle iron, adjusting bolts, and vertical sliding groove of the vertical plate, and the height is fixed by tightening the bolts after adjustment;

[0098] 4. Material supply control device: The slurry conveying path is as follows: material supply tank → high pressure feed pipe → electronic flow valve → solenoid valve → nozzle. The electronic flow valve controls the slurry output flow rate, and the solenoid valve controls the pipeline opening and closing. The material supply tank is connected to a high pressure air inlet pipe, which pushes the slurry along the pipeline by air pressure.

[0099] 5. Dustproof device: The upper dustproof cabinet is located above the transmission roller, and the lower dustproof cabinet is located below the transmission roller. The two together form a sealed spraying cavity. Dust suction ports are opened on the side walls of the cavity. The dust suction ports are connected to dust suction pipes and then to a dust suction fan to continuously extract floating dust inside the cavity. The front and rear sides of the upper dustproof cabinet have inlet and outlet ports, which serve as channels for the ceramic substrate to enter and exit. Photoelectric sensor transmitters and receivers are respectively installed on both sides of the channels.

[0100] 6. Electrical Control System: The main control unit serves as the central control unit, receiving material detection signals from photoelectric sensors at the inlet and outlet, and synchronously outputting control signals to the geared motor, solenoid valve, and electronic flow valve to achieve coordinated control of conveying and spraying.

[0101] Complete machine assembly operation process:

[0102] 1. Place the frame 1 on the ground, level and fix it, weld and lock the support plate 16 to the corresponding position at the bottom of the frame, and fix the vertical plate 15 vertically to the top surface of the support plate 16 to complete the basic installation of the height adjustment frame 6.

[0103] 2. Angle iron 18 fits against the inner side of vertical plate 15. Adjusting bolts pass horizontally through the vertical plate adjustment groove 17 and are screwed into the angle iron screw hole 19. The lower right angle surface of the angle iron is bolted to the nozzle mounting plate 4. The nozzles 5 are evenly arranged and fixed on the surface of the nozzle mounting plate 4.

[0104] 3. Multiple drive rollers 2 are mounted in parallel on the upper part of the frame. Each drive roller is equipped with a drive gear at its end. A chain is sleeved on the outside of all the drive gears to complete the linkage assembly. The geared motor 3 is fixed to the side bracket of the frame, and the coupling is connected to the output shaft at the end of the drive roller.

[0105] 4. The dustproof lower cabinet 11 is hoisted and fixed to the lower part of the frame, covering the entire adjustable spraying device; the dustproof upper cabinet 10 is hoisted and fixed to the upper part of the frame, covering the transmission roller 2. The dustproof upper cabinet has a feed port 13 and a discharge port on the front and rear sides, and photoelectric sensors 14 are installed on both sides of the feed port and the discharge port respectively.

[0106] 5. Dustproof upper cabinet 10. Dustproof lower cabinet 11. Dust suction port 12 is reserved on the side wall. The dust suction pipe is sealed and connected to the dust suction port. All dust suction pipes are connected to the air intake of the dust suction fan.

[0107] 6. The feeding hopper 20 is placed outside the equipment. One end of the high-pressure feed pipe 7 extends below the liquid surface of the feeding hopper, and the other end is connected in series with the electronic flow valve 9 and the solenoid valve 8, and then branched to each nozzle 5. The high-pressure air inlet pipe is connected to the sealing interface of the feeding hopper lid.

[0108] 7. The control host 21 is fixedly installed on the side of the frame in the operating position, and the wiring is completed to complete the electrical connection of the geared motor, solenoid valve, electronic flow valve and photoelectric sensor.

[0109] Complete Implementation Example of Standardized Spraying Process

[0110] This embodiment uses the above-mentioned ceramic substrate surface treatment spraying machine. The ceramic polymer materials are used as the spraying raw materials to process 600mm×600mm ceramic brick substrates with a thickness of 10mm. All processes from S1 to S7 are executed completely, and the intermediate standard values ​​are selected for the actual operation parameters of each step.

[0111] S1, Raw material pretreatment

[0112] S11, the ceramic polymer materials in the water washing sand production line are used to form a formula raw material. The raw material is put into the vibrating screening equipment and graded by a 100-mesh standard screen. The vibrating screening is carried out for 8 minutes to remove stones, coarse sand, and coarse plant fiber impurities, and the fine powder under the screen is collected.

[0113] S12, take 100kg of sieved powder, add 150kg of clean water (solid-liquid mass ratio 1:1.5), and add 1.2kg of ceramic water-based binder to the mixing tank;

[0114] S13, set the stirring equipment speed to 400r / min, stir continuously for 15min, and let stand for 5min to defoam after stirring to obtain a homogeneous ceramic polymer material formulation slurry. The slurry is free of lumps and obvious coarse particle sedimentation.

[0115] S2, Equipment preparation and commissioning, including:

[0116] S21. Pour all the slurry prepared in S1 into the feeding tank 20, seal the tank lid, and connect the high-pressure air inlet pipe; adjust the air supply pressure regulating valve to stabilize the air supply pressure at 0.35MPa.

[0117] S22, power on the whole machine, start the dust collection fan, adjust the frequency conversion parameters of the fan to make the dust collection port inside the dust cabinet stable negative pressure -200Pa;

[0118] S23, start the geared motor, adjust the motor frequency converter output, and set the transmission roller conveyor line speed to 0.5m / min;

[0119] S24, Set the output flow rate of a single nozzle to 220mL / min on the control host operation interface, and lock the electronic flow valve parameters;

[0120] S25, loosen all adjusting bolts on the height adjustment bracket, adjust the height of the nozzle mounting plate along the vertical slide groove of the vertical plate, measure the distance between the top of the nozzle and the bottom surface of the ceramic substrate to 10mm, and tighten all adjusting bolts to complete the positioning.

[0121] S3, Substrate Conveying: The 600mm×600mm ceramic tile substrate is manually placed smoothly on the surface of the transmission roller 2 from the dustproof upper cabinet inlet. The reduction motor drives all the transmission rollers to rotate synchronously and uniformly, and the ceramic substrate smoothly enters the dustproof sealed cavity along the conveying direction.

[0122] S4, Automatic Spraying: The photoelectric sensors on both sides of the feed inlet are blocked by the ceramic substrate, and the sensors transmit a high-level material detection signal to the control host; the control host outputs a control signal, the solenoid valve is turned on and the electronic flow valve is opened; the 0.35MPa high-pressure slurry in the feeding tank is transported to each nozzle 5 along the high-pressure feed pipe 7, and the nozzle passes through the gap of the transmission roller from bottom to top to continuously spray the bottom surface of the ceramic tile; the single nozzle outputs a stable slurry flow rate of 220mL / min, the substrate passes through at a uniform speed, and the bottom surface is completely covered with a layer of slurry coating.

[0123] S5, Dust prevention and collection: The dust extraction fan runs continuously throughout the spraying process. The dustproof upper cabinet 10 and dustproof lower cabinet 11 form a sealed cavity. The slurry droplets and dry fine dust generated during spraying are collected into the dust extraction pipe through the dust extraction ports 12 of the cabinet. Under the action of -200Pa negative pressure, they are continuously extracted and uniformly transported to the dust collection box for storage. No dust is scattered outward from the inlet and outlet.

[0124] S6, Material Interruption Control: After the ceramic substrate has completely passed through the outlet position, the optical path of the outlet photoelectric sensor is restored to conduction, transmitting a low-level signal of no material to the control host; the control host issues a shutdown command, the solenoid valve 8 cuts off the high-pressure feed pipe, all nozzles synchronously stop slurry output, the spraying process is suspended, and the geared motor continues to run, waiting for the next substrate to be fed.

[0125] S7, Finished Product Output and Air Drying: The ceramic tile substrate with the bottom coating completed is sent out of the equipment from the discharge port by the transmission roller and transferred to the room temperature natural air drying area. The ambient temperature is 22℃ and there is no forced air blowing. It is left to air dry for 12 minutes. The moisture on the surface of the coating has initially evaporated and the coating has completed basic curing. It is then transferred to the next process of ceramic edge grinding and glazing.

[0126] Batch continuous production operation cycle: Repeat steps S3 to S7, continuously feed ceramic substrate, and the equipment automatically switches between spraying and stop spraying states based on photoelectric sensor signals. The entire set of process parameters remains fixed throughout the process to continuously complete the spraying operation on the bottom surface of the ceramic substrate.

[0127] This invention enables automated assembly line production through a conveying device, an adjustable spraying device, and a material supply control device, resulting in high production efficiency. Sensor 14 monitors whether there is material on the conveying device to control the operation of the adjustable spraying device. If sensor 14 detects material on the conveying device, the control host 21 opens the control valve 8, and the spray nozzle 5 sprays upwards. If sensor 14 detects no material on the conveying device, the control host 21 closes the control valve 8, and the spray nozzle 5 stops working. This achieves automatic monitoring and control of production, eliminating the need for manual labor, resulting in a high degree of automation and high production efficiency.

[0128] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. 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 method for spraying a coating onto a ceramic substrate surface, characterized in that, The coating material is composed of ceramic polymer materials and includes: S1, pre-treated raw materials, including: collecting the ceramic polymer material composition formula, sequentially completing sieving, adding water and additives for conditioning and stirring, to prepare a homogeneous ceramic polymer material composition formula slurry with stable spray flowability; wherein, the ceramic polymer material composition formula includes a basic solid phase matrix and a liquid phase conditioning system as modifying additives, wherein the solid phase matrix of the basic solid phase matrix, after being sieved through an 80-120 mesh vibrating sieve, has a total mass of 100 parts, including 62 parts of quartz fine powder, 21 parts of kaolin ultrafine powder, 9 parts of talc micro powder, 5 parts of alumina ultrafine powder, and 3 parts of polymer modified powder; wherein, the quartz... The fine powder is silica with a particle size of 100–180 μm; the kaolin ultrafine powder is a layered aluminosilicate clay mineral; the polymer-modified powder is 120-mesh polyacrylate micro powder; the liquid phase component of the liquid-phase blending system includes 110–165 parts by weight of industrial deionized water and 10–15 parts by weight of water-based polymeric additives, wherein the industrial deionized water is the dispersion medium; the water-based polymeric additives are liquid-state compound type, including: 40 wt% sodium polyacrylate dispersant, 35 wt% water-based polyurethane emulsion, 15 wt% silicone defoamer, and 10 wt% carboxymethyl cellulose thickener; S2, Prepare the equipment, including: Powering on the entire spraying machine, starting the dust extraction fan, geared motor and air supply system, and adjusting the high-pressure air supply pressure, the output flow of the electronic flow valve and the negative pressure value of the dust extraction fan in sequence. S3, conveying the substrate, including: placing the ceramic substrate to be sprayed from the dustproof upper cabinet inlet onto the surface of the transmission rollers, the geared motor driving all the transmission rollers to rotate synchronously through the chain, and the ceramic substrate passing through the spraying cavity at a uniform speed along the conveying direction; S4, automatic spraying is performed, including: after the photoelectric sensor at the feed inlet detects that the ceramic substrate has entered the cavity, it transmits a material presence signal to the control host; the control host issues an opening command, the solenoid valve is turned on and the electronic flow valve is opened, and the high-pressure slurry in the feed tank is transported to each nozzle along the high-pressure feed pipe; the nozzle sprays the slurry upward through the gap of the transmission roller to complete the spraying of the lower surface of the ceramic substrate in the moving state; according to the thickness specification of the ceramic substrate, the vertical height of the nozzle mounting plate is adjusted in advance by the height adjustment bracket to limit the distance between the nozzle and the bottom surface of the substrate. S5, dust prevention and collection, including: the dust extraction fan keeps running continuously throughout the spraying process, the dust-proof upper cabinet and the dust-proof lower cabinet together form a closed spraying cavity, and the mist slurry dust and dry fine powder generated during spraying are continuously extracted and collected by negative pressure through the dust extraction port and dust extraction pipe of the cabinet. S6, controlling material spray interruption, including: when the photoelectric sensor at the discharge port detects that no ceramic substrate is passing on the conveyor line, it transmits a no-material signal to the control host; the control host issues a shutdown command, the solenoid valve cuts off the slurry conveying pipeline, and all nozzles stop spraying synchronously. S7, Output the finished product, including: the ceramic substrate with the bottom surface sprayed is sent out of the spraying equipment from the discharge port by the transmission roller, and transferred to the room temperature air drying station for air drying post-treatment. After the sprayed coating is initially cured, it is transferred to the ceramic deep processing process.

2. The method for spraying a ceramic substrate surface according to claim 1, characterized in that, The sieving process in S1 includes: using a vibrating sieving device to grade and filter the original ceramic polymer materials according to their composition, with a screen mesh size of 80-120 mesh, to remove stones, coarse sand, and coarse fibers, and to obtain fine powder.

3. The method for spraying a ceramic substrate surface according to claim 2, characterized in that, The conditioning and stirring in S1 includes: adding water and ceramic binder to the sieved powder, with a solid-liquid mass ratio of 1:1.2 to 1:1.8, a stirring speed of 300 to 500 r / min, and a stirring time of 10 to 20 min.

4. The method for spraying a ceramic substrate surface according to claim 3, characterized in that, The high-pressure slurry in the feed tank of S4 is transported to each nozzle along the high-pressure feed pipe, including: the high-pressure air inlet pipe of the feed tank provides a constant air supply pressure of 0.2 to 0.5 MPa.

5. The method for spraying a ceramic substrate surface according to claim 4, characterized in that, The spraying of slurry upward through the gap between the drive rollers includes: the drive rollers providing a conveying linear speed of 0.3 to 0.8 m / min, and the ceramic substrate to be coated passing through at a uniform speed.

6. The method for spraying a ceramic substrate surface according to claim 5, characterized in that, The step of adjusting the vertical height of the nozzle mounting plate in advance using the height adjustment bracket to limit the distance between the nozzle and the bottom surface of the substrate includes: loosening the adjusting bolts, moving the angle iron and the nozzle mounting plate along the vertical slide groove of the vertical plate, controlling the distance between the nozzle and the bottom surface of the substrate to 5-15mm, and tightening the locking bolts for positioning after adjustment.

7. The method for spraying a ceramic substrate surface according to claim 6, characterized in that, The process of spraying the lower surface of the ceramic substrate in motion includes: independently controlling the output flow rate of the slurry from a single nozzle to 150-300 mL / min using an electronic flow valve.

8. The method for spraying a ceramic substrate surface according to claim 7, characterized in that, The cabinet's dust extraction port creates a negative pressure for dust extraction, with the negative pressure at the port remaining stable at -300 to -100 Pa, continuously extracting dust from the sealed cavity.

9. The method for spraying a ceramic substrate surface according to claim 8, characterized in that, The photoelectric sensor in S6 collects the presence or absence of electrical signals in the material in real time and transmits them to the control host. The host then controls the opening and closing of the solenoid valve, the start and stop of the reduction motor, and the automatic switching between spraying and stopping.

10. The method for spraying a ceramic substrate surface according to claim 9, characterized in that, The post-drying process includes: after the substrate is discharged, it is naturally air-dried at room temperature for 8-15 minutes, and the sprayed coating is initially cured.

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