CN210958424U

CN210958424U - System for preparing composite cover plate

Info

Publication number: CN210958424U
Application number: CN201922420406.6U
Authority: CN
Inventors: 吴沙鸥; 杨青松; 徐信林; 李婵; 冼锐炜; 孔雪芳; 贺鹏华; 毕倩兰; 李方伟
Original assignee: Dongguan Taotao New Material Technology Co ltd
Current assignee: Dongguan Taotao New Material Technology Co ltd
Priority date: 2019-12-26
Filing date: 2019-12-26
Publication date: 2020-07-07
Anticipated expiration: 2029-12-26

Abstract

The utility model discloses a system for preparing composite cover plate, include: the casting device is used for preparing the membrane and the porous membrane; the 3D support plate die is connected with the casting device and used for laminating the membrane and the porous membrane and performing vacuum-pumping encapsulation; the isostatic pressing device is connected with the 3D carrier plate die and is used for carrying out isostatic pressing treatment on the encapsulated 3D carrier plate die to obtain a blank body; the sintering device is connected with the isostatic pressing device and is provided with a green body inlet and a ceramic green body outlet; a first post-processing unit having a ceramic body inlet and a 3D ceramic outlet; the injection molding device is provided with an injection molding feeding inlet and a 3D plastic lining outlet; the glue dispensing device is provided with a 3D ceramic piece inlet, a 3D plastic lining inlet and a bonding piece outlet; a second aftertreatment unit having a bond inlet and a composite deck outlet. Compared with the in-mold injection molding, the composite cover plate manufactured by the system has high comprehensive yield, and compared with the traditional dispensing process, the bonding strength and reliability of the 3D ceramic part and the 3D plastic lining are greatly improved.

Description

System for preparing composite cover plate

Technical Field

The utility model belongs to the preparation field of 3D outward appearance structure particularly, the utility model relates to a system of compound apron of preparation.

Background

With the development of technology, the materials of the appearance structural parts of 3C products are continuously evolving. Taking a mobile phone backboard as an example, the mainstream backboard material is gradually changed from plastic and aluminum alloy into glass, ceramic and other materials. However, the ceramic appearance structural member has a large limitation in application to 3C products due to the high density of the ceramic. In order to break through the bottleneck and meet the requirements of terminal customers, engineering technicians develop a nano injection molding technology and a dispensing process to combine ceramics and plastics. The technology for manufacturing the novel composite 3C structural part combines the characteristics of high hardness, abrasion resistance and good texture of ceramics and the characteristics of low density, high toughness, low cost, easy manufacture and the like of plastic parts.

However, the existing glue dispensing process has an influence on the practical engineering application due to the problems of glue adhesion reliability, glue overflow and the like. The nano injection molding technology is more and more common in engineering practice due to the relative maturity and high automation degree of the injection molding technology. The existing nano injection molding technology generally comprises the steps of directly injecting a ceramic substrate after grinding and polishing processing or injecting the ceramic substrate after treating the surface by chemical corrosion, physical spraying, laser texturing, sanding and the like. The reliability of the ceramic body bonded in the latter manner is greatly increased, and the bonding strength is also greatly improved. However, it is extremely difficult to perform nano-injection molding on 3D ceramics, and at present, nano-injection molding can only be performed on 2D products (flat sheets).

Therefore, the existing technology for preparing the 3D appearance structural member needs to be further improved.

SUMMERY OF THE UTILITY MODEL

The present invention aims at solving at least one of the technical problems in the related art to a certain extent. To this end, it is an object of the present invention to provide a system for manufacturing a composite cover plate. Compared with the in-mold injection molding, the composite cover plate manufactured by the system has high comprehensive yield, and compared with the traditional dispensing process, the bonding strength and reliability of the 3D ceramic part and the 3D plastic lining are greatly improved.

In an aspect of the present invention, the utility model provides a system for preparing composite cover plate, according to the utility model discloses an embodiment, this system includes:

the casting device is used for respectively preparing the membrane and the porous membrane;

the 3D support plate die is connected with the casting device, and the 3D support plate die is used for laminating the membrane and the porous membrane and performing vacuum-pumping encapsulation after the membrane and the porous membrane are laminated;

the isostatic pressing device is connected with the 3D carrier plate die and is used for carrying out isostatic pressing treatment on the 3D carrier plate die encapsulated with the diaphragm and the porous diaphragm so as to obtain a blank;

the sintering device is connected with the isostatic pressing device and is provided with a green body inlet and a ceramic green body outlet;

the first post-processing unit is provided with a ceramic blank inlet and a 3D ceramic piece outlet, and the ceramic blank inlet is connected with the ceramic blank outlet;

an injection molding device having an injection molding feed inlet and a 3D plastic liner outlet;

the glue dispensing device is provided with a 3D ceramic inlet, a 3D plastic lining inlet and a bonding part outlet, the 3D ceramic inlet is connected with the 3D ceramic outlet, and the 3D plastic lining inlet is connected with the 3D plastic lining outlet;

a second aftertreatment unit having a bonding element inlet and a composite cover plate outlet, the bonding element inlet being connected to the bonding element outlet.

According to the system for preparing the composite cover plate, the membrane and the porous membrane are respectively prepared by adopting the tape casting process, and the thicknesses of the membrane and the porous membrane can be freely adjusted according to requirements; further, the obtained membrane and the porous membrane are stacked and sent to a 3D carrier plate die after separation and adhesion treatment, the number and stacking sequence of the membrane and the porous membrane can be adjusted according to product requirements in the stacking process, and vacuumizing encapsulation is performed after stacking is finished, so that subsequent isostatic pressing treatment is facilitated; further, carrying out isostatic pressing treatment on the 3D carrier plate die laminated with the diaphragm and the porous diaphragm to obtain a 3D blank, and further sintering and carrying out first post-treatment to obtain a 3D ceramic part with a porous binding surface; the rough surface of the binding surface which is a 3D plastic lining can be obtained by directly carrying out injection molding on the injection molding feed; under the spot gluing process, the obtained 3D ceramic part and the 3D plastic lining can be attached, and because the attaching surface of the 3D ceramic part is a porous surface, and the attaching surface of the 3D plastic lining is also a rough surface, the contact area between the 3D plastic lining and the 3D ceramic part is greatly increased, the bonding strength and the reliability of the 3D plastic lining and the 3D ceramic part are greatly improved, and the ceramic-plastic composite cover plate can be obtained after the second post-treatment. Compared with the in-mold injection molding, the process successfully avoids the contradiction that the gap reserved by the matching of the ceramic and the injection mold when the 3D ceramic part is in-mold injection molding and the ceramic is a brittle material and has no deformation, so that the 3D ceramic part and the 3D plastic lining can be reliably compounded, the comprehensive yield of the manufactured composite cover plate is high, and the manufacturing cost can be effectively controlled; furthermore, compared with the traditional dispensing process, the bonding surface area between the 3D ceramic piece and the 3D plastic lining is obviously increased, and the bonding strength and the reliability of the two are greatly improved.

In addition, the system for preparing a composite cover plate according to the above embodiment of the present invention may further have the following additional technical features:

optionally, the casting device is selected from a tape casting machine and/or a steel tape casting machine.

Optionally, the isostatic press is selected from at least one of a hot press, a cold isostatic press, a warm isostatic press

Optionally, the sintering device is a box furnace and/or a tunnel furnace.

Optionally, the first post-processing unit comprises at least one of a laser cutting device, a CNC device, a thinning device, a cleaning device, an annealing device, a grinding device, a polishing device, and a perforating device.

Optionally, the injection molding device is selected from at least one of a vertical injection molding machine, a horizontal injection molding machine and an all-electric injection molding machine.

Optionally, the dispensing device is selected from at least one of a single-component dispenser and a two-component dispenser.

Optionally, the second post-treatment unit comprises at least one of a pressure curing device and a deburring device.

Additional aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.

Drawings

The above and/or additional aspects and advantages of the present invention will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:

fig. 1 is a schematic structural view of a system for manufacturing a composite decking according to an embodiment of the present invention;

fig. 2 is a schematic flow chart of a method for manufacturing a composite cover plate according to an embodiment of the present invention;

fig. 3 is a schematic view of a 3D carrier plate mold in the embodiment.

Detailed Description

Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the drawings are exemplary and intended to be used for explaining the present invention, and should not be construed as limiting the present invention.

In the description of the present invention, it is to be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", and the like, indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for convenience of description and simplicity of description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore, should not be construed as limiting the present invention.

Furthermore, the terms "first", "second" and "first" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one such feature. In the description of the present invention, "a plurality" means at least two, e.g., two, three, etc., unless specifically limited otherwise.

In the present invention, unless otherwise expressly stated or limited, the terms "mounted," "connected," and "fixed" are to be construed broadly and may, for example, be fixedly connected, detachably connected, or integrally formed; can be mechanically or electrically connected; they may be directly connected or indirectly connected through intervening media, or they may be connected internally or in any other suitable relationship, unless expressly stated otherwise. The specific meaning of the above terms in the present invention can be understood according to specific situations by those skilled in the art.

In the present application, unless expressly stated or limited otherwise, the first feature may be directly on or directly under the second feature or indirectly via intermediate members. Also, a first feature "on," "over," and "above" a second feature may be directly or diagonally above the second feature, or may simply indicate that the first feature is at a higher level than the second feature. A first feature being "under," "below," and "beneath" a second feature may be directly under or obliquely under the first feature, or may simply mean that the first feature is at a lesser elevation than the second feature.

In an aspect of the present invention, the utility model provides a system for preparing composite cover plate, according to the utility model discloses an embodiment, refer to fig. 1, this system includes: the casting device 100, the 3D carrier plate mold 200, the isostatic pressing device 300, the sintering device 400, the first post-processing unit 500, the injection molding device 600, the dispensing device 700, and the second post-processing unit.

According to an embodiment of the present invention, the casting apparatus 100 is used to prepare a membrane sheet and a porous membrane sheet, respectively. The inventor finds that the membrane and the porous membrane prepared by the process have the advantages of high speed, high automation degree, high efficiency, uniform tissue structure, good product quality and the like. The specific preparation method of the first ceramic slurry and the second ceramic slurry is not particularly limited, and may be selected by those skilled in the art according to actual needs, for example, the ceramic powder obtained by fine grinding and calcination may be added to a solvent, and if necessary, an anti-coagulant, a defoaming agent, a sintering accelerator, and the like may be added to the mixture and wet mixed and ground; then adding adhesive, plasticizer, lubricant, etc. to mix and grind to form stable slurry with good fluidity. The specific type of the ceramic powder may be at least one of zirconia, alumina, aluminum nitride, and strontium aluminate, for example, zirconia, and the color of the zirconia ceramic is not particularly limited, and may be selected by those skilled in the art according to actual needs, for example, at least one selected from black zirconia ceramic, white zirconia ceramic, dark green zirconia ceramic, pink zirconia ceramic, and the like. The ceramic is high in quality and moist in color, and the prepared composite cover plate has good appearance expressive force. It should be noted that the specific formulations of the first ceramic slurry and the second ceramic slurry may be the same or different, and those skilled in the art can select them according to actual needs. Further, the specific type of the first casting device is not particularly limited, and may be selected by those skilled in the art according to actual needs, for example, at least one of a tape casting machine and a steel tape casting machine.

Further, the pore-forming agent added in the step can volatilize in the subsequent sintering treatment process, and the 3D ceramic piece with the porous binding surface is obtained. Further, the specific type of the pore-forming agent is not particularly limited, and may be selected by those skilled in the art according to actual needs, and may be, for example, at least one selected from carbon powder, plastic powder, carbonate, sulfur powder, phosphorus powder, and graphite powder, wherein the carbonate is a carbonate that can be decomposed at high temperature, and may be, for example, calcium carbonate. The inventors have found that when the pore-forming agent is a high-temperature decomposition inorganic substance such as carbonate, the substance is decomposed and volatilized at a high temperature to generate pores; when the pore-forming agent is a high-temperature ablation inorganic substance such as carbon powder, the substance can react with oxygen in the air at a high temperature to become gas to escape, so that small pores are generated; when the pore-forming agent is a high-temperature ablative organic substance such as plastic powder, specifically PVB powder, PVA powder and PC powder, the substance can react with oxygen in the air at a high temperature to become gas to escape, so that small pores are generated.

Further, the mass ratio of the ceramic powder to the pore-forming agent in the second ceramic slurry is not particularly limited, and can be selected by a person skilled in the art according to actual needs, for example, the mass ratio can be 1.5 to 150: 1, for example, may be 1.5/15/30/45/60/75/90/105/120/135/150: 1. the inventor finds that when the ratio of the ceramic powder to the pore-forming agent is too low, the content of the pore-forming agent is too high, and the volume occupied by the pores in the porous membrane is too large, so that the bonding strength between the porous surface and the 3D plastic lining is greatly reduced; when the ratio of the ceramic powder to the pore-forming agent is too high, the volume occupied by the pores in the porous membrane is too small, so that the pore diameter of the porous surface and the number of the pores are greatly reduced, and the reduction of the bonding strength between the 3D ceramic part and the 3D plastic lining is also reduced.

According to the utility model discloses an embodiment, 3D support plate mould 200 links to each other with casting device 100, and 3D support plate mould is used for stromatolite diaphragm and porous diaphragm to carry out evacuation envelope after piling up. Specifically, the specific manner of stacking the membrane sheets and the porous membrane sheets is not particularly limited, for example, one or more membrane sheets may be first placed on a 3D carrier plate mold, and then one or more porous membrane sheets may be stacked on the one or more membrane sheets, or one or more porous membrane sheets may be first placed on the 3D carrier plate mold, and then one or more membrane sheets may be stacked on the one or more porous membrane sheets, and in the stacking process, the specific number of membrane sheets and porous membrane sheets is not particularly limited, and those skilled in the art may select the specific number of membrane sheets and porous membrane sheets according to the actual needs, for example, the specific number of membrane sheets and porous membrane sheets may be determined according to the thicknesses of the membrane sheets and porous membrane sheets and the needs of the final product.

According to the utility model discloses an embodiment, isostatic pressing device 300 links to each other with 3D support plate mould 200, and isostatic pressing device is used for carrying out the isostatic pressing to encapsulating the 3D support plate mould that has diaphragm and porous diaphragm and handle to obtain the body. The inventor finds that the density between products can be increased by carrying out isostatic pressing treatment on the laminated membrane together with a 3D carrier plate mould. It should be noted that the specific type of isostatic pressing device is not particularly limited, and may be at least one selected from a hot press, a cold isostatic press, and a warm isostatic press. Further, the specific conditions of the isostatic pressing treatment are not particularly limited, and for example, the pressure of the isostatic pressing treatment may be 20 to 300MPa, for example, 20MPa, 50MPa, 80MPa, 110MPa, 140MPa, 170MPa, 200MPa, 230MPa, 260MPa, 290MPa, 300MPa, and the time may be 0.5 to 1800s, for example, 0.5s, 100s, 300s, 500s, 700s, 900s, 1100s, 1300s, 1500s, 1700s, 1800 s. The inventors found that when the isostatic pressure is too small, the cast film is difficult to become completely integrated in the pressing process; the pressure is too high, the equipment acquisition cost is greatly increased, and the improvement on the membrane pressing effect is not obvious; the pressure maintaining time is too short, and the cast membrane is difficult to be completely integrated in the pressing process; the pressing time is too long, the single-machine efficiency of the equipment is influenced, and similarly, the pressure maintaining time is increased in a transitional manner, so that the pressing effect of the membrane is not obviously improved.

According to the utility model discloses an embodiment, sintering device 400 has body entry 401 and ceramic body export 402, and body entry 401 links to each other with isostatic pressing device 300, and is suitable for carrying out sintering treatment with the body to obtain ceramic body. The inventor finds that the porous membrane contains the pore-forming agent, so that the pore-forming agent volatilizes in the sintering treatment process, and the porous membrane layer becomes a porous ceramic layer; meanwhile, as the membrane and the porous membrane contain substances such as a binder and the like, after sintering, the original flaky membrane and the porous membrane and/or the porous membrane and the porous membrane form a tightly combined whole, and after first post-treatment, the 3D ceramic part with the porous binding surface is obtained. It should be noted that the specific type of the sintering device is not particularly limited, and those skilled in the art can select the sintering device according to actual needs, such as a box furnace and/or a tunnel furnace.

According to an embodiment of the present invention, the ratio of the thickness of the porous layer in the 3D ceramic part is not particularly limited, and those skilled in the art can select the ratio according to actual needs, such as 1/3 which may not exceed the thickness of the corresponding 3D ceramic part. The inventor finds that the thickness of the porous layer is too large, which greatly affects the physical properties of the whole product, such as strength reduction, insulation grade reduction and water absorption increase, and the thickness of the porous layer is too large to continuously increase the bonding strength of the ceramic part and the plastic lining.

According to another embodiment of the present invention, the sintering condition is not particularly limited, and those skilled in the art can select the sintering temperature according to actual needs, for example, the sintering temperature can be 1000-1700 ℃, such as 1000 ℃, 1100 ℃, 1200 ℃, 1300 ℃, 1400 ℃, 1500 ℃, 1600 ℃, 1700 ℃, and the heat preservation time can be 5-480 min, such as 5min, 50min, 100min, 150min, 200min, 250min, 300min, 350min, 400min, 450min, 480 min. The inventor finds that the sintering temperature is too low, the ceramic density is too low, and pits are easily generated in the processing process; the sintering temperature is too high, the ceramic has too low density due to over-firing, crystal grains are easy to grow abnormally, and pits are easy to generate in the processing process; the heat preservation time is too short, so that the condition that the sintering degree of the ceramic surface is inconsistent with that of the interior of the ceramic is easy to occur, and the ceramic performance is influenced; the heat preservation time is too long, crystal grains are easy to grow abnormally, and the sintering cost is greatly increased.

According to the utility model discloses an embodiment, first aftertreatment unit 500 has ceramic body entry 501 and 3D pottery export 502, and ceramic body entry 501 links to each other with ceramic body export 402, and is suitable for and carries out first aftertreatment with ceramic body to obtain 3D pottery. The inventors found that, after the post-treatment, a 3D ceramic article having a bonding surface with a porous surface can be obtained. It should be noted that the specific content of the post-processing unit is not particularly limited, and those skilled in the art can select the post-processing unit according to actual needs, and for example, the post-processing unit may include at least one of a laser cutting device, a CNC device, a thinning device, a cleaning device, an annealing device, a grinding device, a polishing device, and a punching device. The inventor finds that the laser cutting device can quickly and efficiently remove the rough edges or rough holes of the ceramic blank; the CNC device can precisely process the appearance, the contour and the punching of the ceramic body; the large water mill, the double-sided grinder and the single-sided grinder can finish ceramic thinning, and the thickness of a ceramic blank is controlled; the ultrasonic cleaning machine can clean floating dust and oil stains on the surface of the ceramic blank; the polishing machine can enable the appearance surface of the ceramic to have a mirror surface effect by polishing the surface of the ceramic; the punching equipment such as CNC device, laser cutting device can be used for processing holes with various shapes on the surface of the ceramic.

According to the utility model discloses an embodiment, device 600 of moulding plastics has injection moulding feed entry 601 and 3D plastic inside lining export 602, and is suitable for the feed of will moulding plastics to mould plastics to obtain 3D plastic inside lining. Specifically, the 3D plastic lining with the rough surface as the binding surface can be obtained through pattern carving, wire drawing and corrosion on the surface of the mold and injection molding. It should be noted that the specific type of the injection molding apparatus is not particularly limited, and those skilled in the art can select the injection molding apparatus according to actual needs, such as at least one selected from a vertical injection molding machine, a horizontal injection molding machine, and an all-electric injection molding machine.

According to an embodiment of the present invention, the specific type of the injection molding feed is not particularly limited, and may be selected by those skilled in the art according to actual needs, such as at least one selected from glass fiber reinforced polycarbonate, glass fiber reinforced polybutylene terephthalate, and glass fiber reinforced polyamide. Furthermore, in the 3D plastic lining, the roughness of the rough surface can be Ra0.1-Ra12.5. The inventors found that if the roughness of the rough surface is too small, the adhesive strength between the adhesive layer and the plastic lining is reduced, resulting in insufficient adhesive strength between the ceramic member and the plastic lining; if the roughness of the rough surface is too large, the thickness of the adhesive layer needs to be increased greatly and the mechanical properties of the plastic lining are affected.

According to the embodiment of the utility model, adhesive deposite device 700 has 3D ceramic member entry 701, 3D plastic lining entry 702 and bonding piece export 703, and 3D ceramic member entry 701 links to each other with 3D ceramic member export 502, and 3D plastic lining entry 702 links to each other with 3D plastic lining export 602, and is suitable for to laminate 3D ceramic member and 3D plastic lining through some glue processes to obtain bonding piece. Under the point gluing process, the obtained 3D ceramic part and the 3D plastic lining can be attached, and because the attaching surface of the 3D ceramic part is a porous surface, the attaching surface of the 3D plastic lining is also a rough surface, the contact area between the 3D plastic lining and the 3D ceramic part is greatly increased, and the bonding strength and the reliability of the 3D ceramic part and the 3D plastic lining are greatly improved. Specifically, a dispensing machine can be used for dispensing on the porous binding surface in the 3D ceramic piece, and then the rough binding surface of the 3D plastic lining is bound with the porous binding surface of the 3D ceramic piece with the glue dispensed. It should be noted that the specific type of the dispensing device is not particularly limited, and those skilled in the art can select the dispensing device according to actual needs, for example, the dispensing device may be selected from at least one of a single component dispenser and a two component dispenser.

According to an embodiment of the present invention, the specific type of glue used in the glue dispensing process is not particularly limited, and may be anaerobic glue and/or epoxy glue. The inventor finds that the anaerobic adhesive and the epoxy adhesive have stronger weather resistance, chemical corrosion resistance and bonding performance. According to the utility model discloses an embodiment, second aftertreatment unit has bonding member entry and compound apron export, and bonding member entry links to each other with bonding member export 703, and is suitable for to carry out the second aftertreatment with bonding member to obtain compound apron. It should be noted that the specific content of the second post-treatment unit is not particularly limited, and those skilled in the art can select the second post-treatment unit according to actual needs, for example, the second post-treatment unit may include a pressure curing device and a deburring device.

For convenience of understanding, the following describes in detail a method for manufacturing a composite cover plate, which is implemented by using the system for manufacturing a composite cover plate, according to an embodiment of the present invention, and with reference to fig. 2, the method includes:

s100: casting the first ceramic slurry

In this step, the first ceramic slurry is subjected to casting treatment to obtain a membrane sheet. The inventor finds that the method for preparing the membrane has the advantages of high speed, high automation degree, high efficiency, uniform tissue structure, good product quality and the like. The specific method for preparing the first ceramic slurry is not particularly limited, and may be selected by those skilled in the art according to actual needs, for example, the ceramic powder may be first finely ground or calcined, and then wet mixed ground with a solvent, and if necessary, an anti-coagulant, a defoaming agent, a sintering accelerator, etc.; then adding adhesive, plasticizer, lubricant, etc. to mix and grind to form stable slurry with good fluidity. The specific type of the ceramic powder may be at least one of zirconia, alumina, aluminum nitride, and strontium aluminate, for example, zirconia, and the color of the zirconia ceramic is not particularly limited, and may be selected by those skilled in the art according to actual needs, for example, at least one selected from black zirconia ceramic, white zirconia ceramic, dark green zirconia ceramic, pink zirconia ceramic, and the like. The ceramic is high in quality and moist in color, and the prepared composite cover plate has good appearance expressive force.

S200: mixing the second ceramic slurry with a pore-forming agent and then carrying out tape casting treatment

In the step, the second ceramic slurry and the pore-forming agent are mixed and then subjected to tape casting treatment, so that the porous membrane is obtained. The inventor finds that the method for preparing the membrane has the advantages of high speed, high automation degree, high efficiency, uniform tissue structure, good product quality and the like. The specific method for preparing the second ceramic slurry is not particularly limited, and may be selected by those skilled in the art according to actual needs, for example, the ceramic powder obtained by fine grinding and calcination may be added to a solvent, and if necessary, an anti-coagulant, a defoaming agent, a sintering accelerator, and the like may be added to the mixture and wet mixed grinding may be performed; then adding adhesive, plasticizer, lubricant, etc. to mix and grind to form stable slurry with good fluidity. The specific type of the ceramic powder may be at least one of zirconia, alumina, aluminum nitride, and strontium aluminate, for example, zirconia, and the color of the zirconia ceramic is not particularly limited, and may be selected by those skilled in the art according to actual needs, for example, at least one selected from black zirconia ceramic, white zirconia ceramic, dark green zirconia ceramic, pink zirconia ceramic, and the like. The ceramic is high in quality and moist in color, and the prepared composite cover plate has good appearance expressive force. It should be noted that the specific formulations of the first ceramic slurry and the second ceramic slurry may be the same or different, and those skilled in the art can select them according to actual needs.

S300: conveying the membrane and the porous membrane into a 3D carrier plate mold after separation and adhesion treatment, vacuumizing and encapsulating, carrying out isostatic pressing treatment together with the carrier plate mold, and sintering and carrying out first post-treatment on the obtained blank

In the step, the membrane and the porous membrane are conveyed into a 3D carrier plate mold after separation and adhesion treatment, vacuum pumping and encapsulation are carried out, then isostatic pressing treatment is carried out together with the carrier plate mold, sintering and first post-treatment are carried out on the obtained blank, and the 3D ceramic piece with the porous binding surface is obtained. Specifically, the specific manner of stacking the membrane sheets and the porous membrane sheets is not particularly limited, for example, one or more membrane sheets may be first placed on a 3D carrier plate mold, and then one or more porous membrane sheets may be stacked on the one or more membrane sheets, or one or more porous membrane sheets may be first placed on the 3D carrier plate mold, and then one or more membrane sheets may be stacked on the one or more porous membrane sheets, and in the stacking process, the specific number of membrane sheets and porous membrane sheets is not particularly limited, and those skilled in the art may select the specific number of membrane sheets and porous membrane sheets according to the actual needs, for example, the specific number of membrane sheets and porous membrane sheets may be determined according to the thicknesses of the membrane sheets and porous membrane sheets and the needs of the final product. And then carrying out isostatic pressing treatment on the laminated membrane together with the 3D carrier plate die so as to increase the density of products. And (3) carrying out isostatic pressing and sintering treatment to obtain the 3D ceramic piece with the bonding surface being a porous surface. The inventor finds that the porous membrane contains the pore-forming agent, so that the pore-forming agent volatilizes in the sintering treatment process, and the porous membrane layer becomes a porous ceramic layer; meanwhile, as the membrane and the porous membrane contain substances such as a binder and the like, after sintering, the original flaky membrane and the porous membrane and/or the porous membrane and the porous membrane form a tightly combined whole, and after first post-treatment, the 3D ceramic part with the porous binding surface is obtained.

According to still another embodiment of the present invention, the specific type of isostatic pressing is not particularly limited, and may be selected by those skilled in the art according to actual needs, for example, at least one selected from hot pressing, cold isostatic pressing, and warm isostatic pressing. Further, the specific conditions of the isostatic pressing treatment are not particularly limited, and for example, the pressure of the isostatic pressing treatment may be 20 to 300MPa, for example, 20MPa, 50MPa, 80MPa, 110MPa, 140MPa, 170MPa, 200MPa, 230MPa, 260MPa, 290MPa, 300MPa, and the time may be 0.5 to 1800s, for example, 0.5s, 100s, 300s, 500s, 700s, 900s, 1100s, 1300s, 1500s, 1700s, 1800 s. The inventors found that when the isostatic pressure is too small, the cast film is difficult to become completely integrated in the pressing process; the pressure is too high, the equipment acquisition cost is greatly increased, and the improvement on the membrane pressing effect is not obvious; the pressure maintaining time is too short, and the cast membrane is difficult to be completely integrated in the pressing process; the pressing time is too long, the single-machine efficiency of the equipment is influenced, and similarly, the pressure maintaining time is increased in a transitional manner, so that the pressing effect of the membrane is not obviously improved.

According to another embodiment of the present invention, the sintering conditions are not particularly limited, and those skilled in the art can select the sintering conditions according to actual needs, for example, the sintering temperature of the sintering process can be 1000-1700 ℃, such as 1000 ℃, 1100 ℃, 1200 ℃, 1300 ℃, 1400 ℃, 1500 ℃, 1600 ℃, 1700 ℃, and the heat preservation time can be 5-480 min, such as 5min, 50min, 100min, 150min, 200min, 250min, 300min, 350min, 400min, 450min, and 480 min. The inventor finds that the sintering temperature is too low, the ceramic density is too low, and pits are easily generated in the processing process; the sintering temperature is too high, the ceramic has too low density due to over-firing, crystal grains are easy to grow abnormally, and pits are easy to generate in the processing process; the heat preservation time is too short, so that the condition that the sintering degree of the ceramic surface is inconsistent with that of the interior of the ceramic is easy to occur, and the ceramic performance is influenced; the heat preservation time is too long, crystal grains are easy to grow abnormally, and the sintering cost is greatly increased.

According to another embodiment of the present invention, the specific type of post-processing is not particularly limited, and may be selected by those skilled in the art according to actual needs, for example, at least one selected from laser cutting, CNC, thinning, cleaning, annealing, grinding, polishing, and punching. The inventor finds that laser cutting can quickly and efficiently remove the rough edges or rough holes of the ceramic body; CNC can precisely process the shape, the contour and the punching of the ceramic body; the ceramic thinning can be completed by large water grinding, double-sided grinding and single-sided grinding, and the thickness of the ceramic blank is controlled; the ultrasonic cleaning can clean floating dust and oil stains on the surface of the ceramic blank; the appearance surface of the ceramic can be made to have a mirror surface effect by polishing the surface of the ceramic; the punching equipment such as CNC and laser cutting can machine holes with various shapes on the surface of the ceramic.

S400: injection molding the injection molding feed

In the step, the injection molding feed is subjected to injection molding to obtain the 3D plastic liner with the rough binding surface. Specifically, the 3D plastic lining with the rough surface as the binding surface can be obtained through pattern carving, wire drawing and corrosion on the surface of the mold and injection molding.

S500: attaching the attaching surface of the 3D ceramic part and the attaching surface of the 3D plastic lining by a glue dispensing process, and carrying out second post-treatment on the obtained bonding part

In the step, the binding surface of the 3D ceramic part and the binding surface of the 3D plastic lining are bound through a glue dispensing process, and the obtained binding part is subjected to second post-treatment to obtain the composite cover plate. The inventor finds that the obtained 3D ceramic part can be attached to the 3D plastic lining under the spot gluing process, and the attaching surface of the 3D ceramic part is a porous surface, and the attaching surface of the 3D plastic lining is also a rough surface, so that the contact area between the 3D plastic lining and the 3D ceramic part is greatly increased, the bonding strength and the reliability of the two parts are greatly improved, and the ceramic-plastic composite cover plate can be obtained after the second post-treatment. Specifically, dispensing can be performed on the porous attaching surface in the 3D ceramic part by using a dispenser, then attaching the rough attaching surface of the 3D plastic liner to the porous attaching surface of the 3D ceramic part on which the adhesive is dispensed, and performing a second post-treatment to obtain the composite cover plate.

According to an embodiment of the present invention, the specific type of glue used in the glue dispensing process is not particularly limited, and may be anaerobic glue and/or epoxy glue. The inventor finds that the anaerobic adhesive and the epoxy adhesive have stronger weather resistance, chemical corrosion resistance and bonding performance.

According to a further embodiment of the invention, the second post-treatment may comprise pressure curing and deburring.

According to the method for preparing the composite cover plate, the membrane and the porous membrane are respectively prepared by adopting the tape casting process, and the thicknesses of the membrane and the porous membrane can be freely adjusted according to requirements; further, the obtained membrane and the porous membrane are stacked and sent to a 3D carrier plate die after separation and adhesion treatment, the number and stacking sequence of the membrane and the porous membrane can be adjusted according to product requirements in the stacking process, and vacuumizing encapsulation is performed after stacking is finished, so that subsequent isostatic pressing treatment is facilitated; further, carrying out isostatic pressing treatment on the 3D carrier plate die laminated with the diaphragm and the porous diaphragm to obtain a 3D blank, and further sintering and carrying out first post-treatment to obtain a 3D ceramic part with a porous binding surface; the rough surface of the binding surface which is a 3D plastic lining can be obtained by directly carrying out injection molding on the injection molding feed; under the spot gluing process, the obtained 3D ceramic part and the 3D plastic lining can be attached, and because the attaching surface of the 3D ceramic part is a porous surface, and the attaching surface of the 3D plastic lining is also a rough surface, the contact area between the 3D plastic lining and the 3D ceramic part is greatly increased, the bonding strength and the reliability of the 3D plastic lining and the 3D ceramic part are greatly improved, and the ceramic-plastic composite cover plate can be obtained after the second post-treatment. Compared with the in-mold injection molding, the process successfully avoids the contradiction that the gap reserved by the matching of the ceramic and the injection mold when the 3D ceramic part is in-mold injection molding and the ceramic is a brittle material and has no deformation, so that the 3D ceramic part and the 3D plastic lining can be reliably compounded, the comprehensive yield of the manufactured composite cover plate is high, and the manufacturing cost can be effectively controlled; furthermore, compared with the traditional dispensing process, the bonding surface area between the 3D ceramic piece and the 3D plastic lining is obviously increased, and the bonding strength and the reliability of the two are greatly improved.

It should be noted that the features and advantages of the above system for manufacturing a composite cover plate are also applicable to the method for manufacturing a composite cover plate, and are not described in detail herein.

The invention will now be described with reference to specific examples, which are intended to be illustrative only and not to be limiting in any way.

Examples

(1) Preparing a pure black 3Y zirconia casting film A with the specification of 200mm × 100mm, 100mm × 0.3mm, 0.3mm and 9.5 percent of glue content by a casting process;

(2) preparing a casting porous membrane B with the specification of 200mm × 100mm, × 0.005mm and the glue content of 20% by a casting process;

(3) sequentially transferring the single porous membrane B and the 3 membranes A to the surface of a 3D carrier plate mould which is subjected to the upper and lower adhesive treatment, as shown in figure 3, and vacuumizing and encapsulating;

(4) after the step (3) is finished, putting the encapsulated diaphragm and the 3D carrier plate mold into warm water isostatic pressing for isostatic pressing treatment, wherein the water temperature is 70 ℃, the pressure maintaining pressure is 150Mpa, and the pressure maintaining time is 300 s;

(5) after the step (4) is finished, unpacking, putting the green body into a furnace, and sintering according to a certain sintering system, wherein the sintering temperature is 1410 ℃, and the temperature is kept for 180 min;

(6) after the step (5) is finished, carrying out laser trimming, CNC (computer numerical control) processing of the shape, single-face thinning, cleaning, annealing, grinding (thinning face), cleaning, annealing, polishing (thinning face) and punching on the sintered blank to obtain a porous zirconia 3D ceramic part with the A-face mirror surface effect and the B-face;

(7) selecting injection molding feed of PC + 30% glass fiber, drying the material, and performing injection molding to obtain a 3D plastic lining;

(8) using AB epoxy structural adhesive to finish adhesive dispensing on the B surface of the 3D ceramic part after the step (6) by using an adhesive dispenser, and then bonding the 3D plastic lining finished in the step (7) with the B surface of the 3D ceramic part after the adhesive dispensing;

(9) and (5) pressurizing, curing and deburring the bonding piece after the step (8) to obtain the ceramic plastic composite cover plate.

In the description herein, references to the description of the term "one embodiment," "some embodiments," "an example," "a specific example," or "some examples," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.

Although embodiments of the present invention have been shown and described, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention, and that variations, modifications, substitutions and alterations can be made to the above embodiments by those of ordinary skill in the art without departing from the scope of the present invention.

Claims

1. A system for making a composite deck, comprising:

2. The system for making a composite deck according to claim 1, wherein said casting device is selected from a tape casting machine and/or a steel tape casting machine.

3. The system for manufacturing a composite decking according to claim 1 or 2 wherein the isostatic press is selected from at least one of a hot press, a cold isostatic press, a warm isostatic press.

4. The system for manufacturing a composite deck according to claim 1, wherein the sintering device is a box furnace and/or a tunnel furnace.

5. The system for manufacturing a composite cover plate according to claim 1, wherein the first post-processing unit comprises at least one of a laser cutting device, a CNC device, a thinning device, a cleaning device, an annealing device, a grinding device, a polishing device, a perforating device.

6. The system for manufacturing a composite cover plate according to claim 1, wherein the injection molding device is selected from at least one of a vertical injection molding machine, a horizontal injection molding machine, and an all-electric injection molding machine.

7. The system for manufacturing a composite cover plate according to claim 1, wherein the dispensing device is selected from at least one of a one-component dispenser and a two-component dispenser.

8. The system for making a composite decking according to claim 1, wherein the second post-treatment unit includes at least one of a press curing apparatus, a de-burring apparatus.