WO2020063205A1 - 一种轻质高强高韧的发泡陶瓷装饰一体板及其制备方法 - Google Patents

一种轻质高强高韧的发泡陶瓷装饰一体板及其制备方法 Download PDF

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WO2020063205A1
WO2020063205A1 PCT/CN2019/101846 CN2019101846W WO2020063205A1 WO 2020063205 A1 WO2020063205 A1 WO 2020063205A1 CN 2019101846 W CN2019101846 W CN 2019101846W WO 2020063205 A1 WO2020063205 A1 WO 2020063205A1
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toughness
strength
foamed
lightweight
integrated board
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PCT/CN2019/101846
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English (en)
French (fr)
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黄聿新
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广西旭腾实业集团有限公司
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Publication of WO2020063205A1 publication Critical patent/WO2020063205A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/002—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising natural stone or artificial stone
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
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    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/045—Polyalkenes
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    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/04—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/08—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds containing halogen
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    • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
    • C04B26/02—Macromolecular compounds
    • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B26/14—Polyepoxides
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    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/34—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
    • C04B28/344—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders the phosphate binder being present in the starting composition solely as one or more phosphates
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    • C04B33/00—Clay-wares
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    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C04B33/132—Waste materials; Refuse; Residues
    • C04B33/1324—Recycled material, e.g. tile dust, stone waste, spent refractory material
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    • C04B33/32—Burning methods
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    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/06—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by burning-out added substances by burning natural expanding materials or by sublimating or melting out added substances
    • C04B38/063—Preparing or treating the raw materials individually or as batches
    • C04B38/0635—Compounding ingredients
    • C04B38/0645—Burnable, meltable, sublimable materials
    • C04B38/068—Carbonaceous materials, e.g. coal, carbon, graphite, hydrocarbons
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    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
    • C—CHEMISTRY; METALLURGY
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    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/5072—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with oxides or hydroxides not covered by C04B41/5025
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    • C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
    • C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
    • C04B41/61—Coating or impregnation
    • C04B41/65—Coating or impregnation with inorganic materials
    • C04B41/68—Silicic acid; Silicates
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    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00482—Coating or impregnation materials
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    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/2038—Resistance against physical degradation
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    • C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
    • C04B2201/30—Mortars, concrete or artificial stone characterised by specific physical values for heat transfer properties such as thermal insulation values, e.g. R-values
    • C04B2201/32—Mortars, concrete or artificial stone characterised by specific physical values for heat transfer properties such as thermal insulation values, e.g. R-values for the thermal conductivity, e.g. K-factors
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    • C04B2201/50—Mortars, concrete or artificial stone characterised by specific physical values for the mechanical strength
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    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
    • C04B2235/3231—Refractory metal oxides, their mixed metal oxides, or oxide-forming salts thereof
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Definitions

  • the invention relates to the field of decorative materials, in particular to a lightweight, high-strength and toughness foamed ceramic decorative integrated board and a preparation method thereof.
  • the materials on the market's existing interior and exterior wall surface decoration layers are mainly ceramic tiles, granite, marble, polyethylene extruded insulation decorative boards, and exterior wall coatings.
  • ceramic tiles, granite, and marble burn a large number of coal mines during the production process. Resources, serious damage to the environment pollution, the tile itself is self-heavy, there is no self-insulation function, a large amount of cement mortar is used in the construction and installation process to wet paste, the process is complex, the service life is short, it is easy to crack and fall off, and the safety hazard is greater; granite And marble itself is a non-renewable mineral resource. It is increasingly demanded in urban development and construction, and the ecological environment is severely damaged during the large-scale mining process.
  • Soft porcelain is a new type of energy-saving and low-carbon decorative material.
  • As a wall decoration material it has the characteristics of light weight, good flexibility, various appearance and modeling, and good weather resistance. It is used as a floor decoration material, which has abrasion resistance, non-slip, Features such as comfortable feet; easy and fast construction, shorter construction period than traditional materials, saving space and cost, and not easy to fall off.
  • the invention patent with the application number of CN201610265638.7 discloses a method for preparing a soft porcelain polyurethane thermal insulation decorative composite board.
  • the flexible soft porcelain is directly prepared on the polyurethane thermal insulation board, so that the composite board can be synthesized at one time.
  • the wind composite board has both the effects of heat insulation and decoration, but the strength is not high and the range of application is limited.
  • the invention patent with the application number of CN201610959101.0 discloses a thermal insulation and decoration integrated decorative tile and a preparation method thereof, which connects the soft porcelain decorative layer and the thermal insulation layer into a whole, and has the functions of decoration and thermal insulation.
  • the facing tile is bonded to the soft porcelain facing layer and the heat-preserving layer by a slurry material, which is prone to cracks, and the facing tile still needs to be improved in terms of strength and toughness.
  • One of the objectives of the present invention is to provide a lightweight, high-strength, and high-strength foamed ceramic decorative integrated board for the above-mentioned problems.
  • the high-toughness decorative surface layer made of soft porcelain and the foamed light-weight material layer are bonded by a die. They are tied together, and then the surface of the high-toughness decorative surface is coated with a wear-resistant coating, which has the effects of good toughness, light weight and high strength, flame retardancy, heat insulation, water resistance, impermeability and aging resistance.
  • a lightweight, high-strength and toughness foamed ceramic decorative integrated board includes a foamed lightweight material layer, a high-toughness decorative surface layer and a wear-resistant coating; the high-toughness decorative surface layer is made of soft porcelain, and The foamed lightweight material layers are bonded together by a stamper, and the wear-resistant coating is coated on the surface of the high-toughness decorative surface layer.
  • the foamed lightweight material layer includes the following raw materials in terms of weight percentage: stone tailings 65 to 85%, graphene 0.05 to 10%, zirconia 0.05 to 10%, high temperature flux 0.05 to 10%, and clay 0.05 to 8%, stabilizer 0.05 ⁇ 5% and degumming agent 0.05 ⁇ 5%.
  • the soft porcelain includes the following raw materials in terms of weight percentage: calcium carbonate 30-50%, graphene 0.05-10%, silicon carbide whiskers 0.05-5%, clay 0.05-10%, AC foaming agent 0.05-5 %, Stabilizers 0.05 to 10%, processing aids 0.05 to 5%, lubricants 0.05 to 10%, high strength resin 30 to 60%, mica 1 to 10%, corundum powder 0.05 to 10%, and colorants 0.05 to 5 %.
  • the wear-resistant coating includes the following raw materials in terms of weight percentage: graphene 1 to 10%, silicon carbide whiskers 0.05 to 5%, corundum powder 3 to 10%, vermiculite 5 to 20%, and kaolin 5 to 20%. , Flame retardant 3 to 10%, nano titanium dioxide 1 to 10%, sodium phosphate 5 to 15%, sodium silicate 10 to 20%, hydroxyethyl cellulose 0.05 to 5%, silicon acrylic emulsion 3 to 6%, and silicon 5 to 10% of sol.
  • the high-strength resin is modified by one or more of polyethylene resin, epoxy resin, and polyvinyl chloride resin.
  • the specific modification method is: selecting polyethylene resin, epoxy resin, One or more of polyvinyl chloride resins are mixed to obtain a mixed resin, and then nano carbon tubes, silicon fine powder, and zinc oxide are added to the mixed resin in an amount of 5 to 15% by mass, and then mixed uniformly. Pellets to get high strength resin.
  • the mass ratio of the carbon nanotubes, silicon fine powder, and zinc oxide is 1 to 5: 3 to 10: 1 to 5.
  • the stone tailings are one or more of granite, feldspar, quartz, sandstone, basalt, diabase, shale, limestone, and marble.
  • the stone tailings are pre-treated first, and the pre-treatment process is: crushing and grinding the stone tailings, and then adding citrate and sodium p-aminobenzenesulfonate for secondary grinding; adding the citrate And sodium p-aminobenzene sulfonate are 0.5 to 1% and 0.1 to 1% of the mass of the stone tailings, respectively.
  • the high temperature flux is one or more of calcined talc, raw talc, diopside and fluorite.
  • the stabilizer is one or more of a liquid barium-zinc composite stabilizer, a liquid calcium-zinc composite stabilizer, a lead salt composite stabilizer, a liquid barium-cadmium and a liquid barium-cadmium-zinc composite stabilizer.
  • the degumming agent is a polycarboxylic acid water-soluble organic material.
  • Another object of the present invention is to provide a method for preparing a lightweight, high-strength, and high-toughness foamed ceramic decorative integrated board.
  • the method has the advantages of high-toughness, light-weight, and high-strength by adopting prefabrication in steps and secondary bonding molding. , Sound insulation, heat insulation, flame retardant, waterproof, impervious, anti-aging, lightweight, lightweight, high-strength, high-toughness foam ceramic decorative integrated board.
  • a method for preparing a lightweight, high-strength and toughness foamed ceramic decorative integrated board includes the following steps:
  • Preparation of high-toughness decorative surface layer Weigh calcium carbonate and graphene according to the formula, mix, crush and grind it, then add other raw materials in the formula, and then enter the high-speed rotary mixer to mix and homogenize for 0.5 ⁇ 3h. After spray granulation treatment, drying, and entering the storage bin for backup, high-toughness decorative surface layer raw materials are obtained.
  • the foamed lightweight powder is fired at a high temperature of 900 to 1300 ° C for 0.5 to 5 hours, taken out after cooling, cut and shaped to obtain a foamed lightweight material layer.
  • the high-toughness decorative surface layer raw material is laminated and micro-foamed under the conditions of a pressure of 2 to 6 MPa, a heating temperature of 180 to 250 ° C, and an extrusion rate of 45 to 100 r / min. , Extrude, and immediately the foamed lightweight layer is bonded and cooled under the condition of the entire surface pressure of 0.5 to 1.0 MPa to form a high-toughness decorative surface layer; after grinding, polishing and cutting, the foamed ceramic decoration is integrated Crude plate.
  • step S5 the sodium phosphate and the sodium silicate are first poured into a container for mixing and heating, and the temperature is controlled at 50-70 ° C; the stirring is continued, and the silica sol is allowed to fully mix to obtain a binder; Then, graphene, silicon carbide whiskers, corundum powder, vermiculite, kaolin, flame retardant, nano titanium dioxide and hydroxyethyl cellulose are mixed according to the proportion, and a silicone-acrylic emulsion is added and mixed for 1 to 2 hours to obtain a mixture; finally Add the binder and the mixture to the mixer, and mix and stir for 1 to 5 hours to make the mixture uniform, to obtain a wear-resistant coating solution.
  • the lightweight, high-strength and toughness foamed ceramic decorative integrated board of the present invention comprises a foamed lightweight material layer, a high-toughness decorative surface layer and a wear-resistant coating; a high-toughness decorative surface layer made of soft porcelain and foamed Light-weight material layers are bonded together by compression molding, and then a wear-resistant coating is applied on the surface of the high-toughness decorative surface layer, which has the effects of good toughness, light weight and high strength, flame retardancy, heat insulation, water resistance, impermeability and aging resistance.
  • the foamed lightweight material layer, high-toughness decorative surface layer, and wear-resistant coating all contain graphene. Through the high specific surface area and high adsorption of graphene, graphene is evenly dispersed on the surface of other materials, making the physical properties of the material It tends to be stable, and assists with each raw material in the formula, and has the effects of anti-aging, anti-corrosion, heat insulation, sound insulation, waterproof and impermeability, fire and fire resistance, light weight and high strength. Adding zirconia, clay, stabilizer, and degumming agent to the foamed lightweight material layer, the toughening mechanism of zirconia is stress-induced phase toughening and microcrack toughening.
  • mica, corundum powder and silicon carbide whiskers are added. Through the two-dimensional sheet structure of graphene, the mechanical properties of the decorative surface material are evenly interspersed in the structure. And waterproof. Silicon carbide whiskers have high fracture strength and elastic modulus, can elastically withstand large strains without permanent deformation, and use silicon carbide to toughen mechanisms such as whisker pull-out, bridging and crack deflection to improve material stability. Sex. The two work together to improve compressive strength and flexibility.
  • the high-strength resin is modified by adding carbon nanotubes, silicon powder and zinc oxide to improve the strength and toughness of the resin, thereby improving the mechanical properties of the high-toughness decorative surface layer.
  • Carbon nanotubes, silica powder, zinc oxide, and resin each play an independent role, and at the same time are interdependent. The mechanical properties of the resin are poor. Only by combining them to form a whole can they effectively play their own role and improve Resin strength.
  • Carbon nanotubes, silica powder, and zinc oxide are used as the skeleton. The proper increase of the content can increase the strength of the resin, but with the increase of the content, the resin structure will relax and cause the strength to decrease. Therefore, the content should be strictly controlled.
  • the use of vermiculite, graphene, nano titanium dioxide, and silicon carbide whiskers can greatly improve the adhesion of the abrasion-resistant coating liquid to the tough decorative surface layer.
  • the coating does not blister, crack, or peel, and plays a role of waterproof, fireproof, heat insulation, corrosion and rust prevention, aging resistance, insulation, etc., extending the service life of the foamed ceramic decorative integrated board .
  • the lightweight, high-strength, and high-strength foamed ceramic decorative integrated board of the present invention has low activity of stone tailings and poor compatibility with other materials, so it is first modified by pretreatment.
  • the modified stone tailings have improved affinity and activity, thereby improving the bonding performance between the materials, and giving the microcrystalline jade high temperature stability and crack resistance.
  • the preparation method of the lightweight, high-strength, and high-strength foamed ceramic decorative integrated board of the present invention through stepwise prefabrication and secondary bonding molding, has high toughness, light weight and high strength, excellent mechanical properties, sound insulation and heat insulation.
  • the high-toughness decorative surface layer is made of soft porcelain, and is bonded to the foamed light-weight material layer through a die.
  • the abrasion-resistant coating is coated on the surface of the high-toughness decorative surface layer.
  • the foamed lightweight material layer includes the following raw materials in terms of weight percentage: stone tailings 75%, graphene 5%, zirconia 5%, high temperature flux 5%, clay 5%, stabilizer 2% and degumming agent 3%.
  • the soft porcelain includes the following raw materials in terms of weight percentage: calcium carbonate 35%, graphene 5%, silicon carbide whiskers 2%, clay 3%, AC foaming agent 2%, stabilizer 3%, processing aid 1%, lubricant 2%, high strength resin 40%, mica 3%, corundum powder 2% and colorant 2%.
  • the wear-resistant coating includes the following raw materials in terms of weight percentage: graphene 5%, silicon carbide whiskers 2%, corundum powder 5%, vermiculite 20%, kaolin 10%, flame retardant 5%, nano titanium dioxide 8 %, Sodium phosphate 10%, sodium silicate 15%, hydroxyethyl cellulose 5%, silicone-acrylic emulsion 5%, and silica sol 10%.
  • the high-strength resin is modified by a polyethylene resin.
  • the specific modification method is: adding 10% by mass of carbon nanotubes, silicon micropowder, and zinc oxide to the polyethylene resin, and then mixing uniformly and extruding Granulation is obtained to obtain a high-strength resin.
  • the mass ratio of the carbon nanotubes, silicon fine powder and zinc oxide is 2: 5: 2.
  • the stone tailings are granite.
  • the stone tailings are first pretreated.
  • the pretreatment process is: crushing and grinding the stone tailings, and then adding citrate and sodium p-aminobenzenesulfonate for secondary grinding; adding citrate and p-amino Sodium besylate is 1% and 0.5% of the stone tailings mass respectively.
  • the high-temperature flux is calcined talc.
  • the stabilizer is a liquid barium-zinc composite stabilizer.
  • the degumming agent is a polycarboxylic acid water-soluble organic material.
  • the preparation method includes the following steps:
  • Preparation of high-toughness decorative surface layer Weigh calcium carbonate and graphene according to the formula, mix, crush and grind it, then add other raw materials in the formula, and then enter the high-speed rotary mixer to mix and homogenize for 2h. After spraying Granulation treatment, drying, entering the storage warehouse for backup, to obtain high-toughness decorative surface layer raw materials.
  • the foamed lightweight powder is fired at a high temperature of 1200 ° C. for 2 hours, taken out after cooling, cut and shaped to obtain a foamed lightweight material layer.
  • the preparation method of the abrasion-resistant coating liquid is as follows: first, the sodium phosphate and sodium silicate are poured into a container and mixed and heated, and the temperature is controlled at 60 ° C; constantly stirring, and the silica sol is allowed to fully mix to obtain a binder. ; Then, according to the proportion of graphene, silicon carbide whiskers, corundum powder, vermiculite, kaolin, flame retardants, nano titanium dioxide and hydroxyethyl cellulose, add silicon-acrylic emulsion, stir and mix for 1.5h to obtain a mixture; Add the binder and the mixture to the blender, mix and stir for 3h, and make it mix well to obtain a wear-resistant coating solution.
  • the high-toughness decorative surface layer is made of soft porcelain, and is bonded to the foamed light-weight material layer through a die.
  • the abrasion-resistant coating is coated on the surface of the high-toughness decorative surface layer.
  • the foamed lightweight material layer includes the following raw materials in terms of weight percentage: 85% of stone tailings, 5% of graphene, 3% of zirconia, 2% of high-temperature flux, 3% of clay, 1% of stabilizer, and degumming agent 1%.
  • the soft porcelain includes the following raw materials in terms of weight percentage: calcium carbonate 40%, graphene 5%, silicon carbide whiskers 2%, clay 3%, AC foaming agent 2%, stabilizer 3%, processing aid 2%, lubricant 5%, high strength resin 30%, mica 5%, corundum powder 2% and colorant 1%.
  • the wear-resistant coating includes the following raw materials in terms of weight percentage: graphene 5%, silicon carbide whiskers 3%, corundum powder 8%, vermiculite 15%, kaolin 15%, flame retardant 5%, nano titanium dioxide 10 %, Sodium phosphate 15%, sodium silicate 15%, hydroxyethyl cellulose 4%, silicone acrylic emulsion 4%, and silica sol 6%.
  • the high-strength resin is modified by polyethylene resin, and the specific modification method is: adding 5% of carbon nanotubes, silicon micronized powder, and zinc oxide to the polyethylene resin, and then mixing them uniformly and extruding Granulation is obtained to obtain a high-strength resin.
  • the mass ratio of the carbon nanotubes, silicon fine powder and zinc oxide is 3: 6: 2.
  • the stone tailings are feldspar, quartz and shale.
  • the stone tailings are first pretreated.
  • the pretreatment process is: crushing and grinding the stone tailings, and then adding citrate and sodium p-aminobenzenesulfonate for secondary grinding; adding citrate and p-amino Sodium besylate is 0.6% and 0.2% of the stone tailings mass, respectively.
  • the high-temperature flux is diopside and fluorite.
  • the stabilizer is a liquid calcium-zinc composite stabilizer and a liquid barium-cadmium-zinc composite stabilizer.
  • the preparation method includes the following steps:
  • Preparation of high-toughness decorative surface layer Weigh calcium carbonate and graphene according to the formula, mix, crush and grind it, then add other raw materials in the formula, and then enter the high-speed rotary mixer to mix and homogenize for 3h. After spraying Granulation treatment, drying, entering the storage warehouse for backup, to obtain high-toughness decorative surface layer raw materials.
  • the foamed lightweight powder is fired at a high temperature of 1300 ° C. for 0.5 h, taken out after cooling, cut and shaped to obtain a foamed lightweight material layer.
  • the preparation method of the abrasion-resistant coating liquid is as follows: first, the sodium phosphate and sodium silicate are poured into a container and mixed and heated, and the temperature is controlled at 70 ° C; constantly stirring, and the silica sol is allowed to fully mix to obtain a binder. ; Then, according to the proportion of graphene, silicon carbide whiskers, corundum powder, vermiculite, kaolin, flame retardants, nano titanium dioxide and hydroxyethyl cellulose, add silicon-acrylic emulsion, stir and mix for 1 h to obtain a mixture; finally Add the binder and the mixture to the mixer, mix and stir for 4h, and make them mix evenly to obtain a wear-resistant coating solution.
  • the high-toughness decorative surface layer is made of soft porcelain, and is bonded to the foamed light-weight material layer through a die.
  • the abrasion-resistant coating is coated on the surface of the high-toughness decorative surface layer.
  • the foamed lightweight material layer includes the following raw materials in terms of weight percentage: stone tailings 65%, graphene 10%, zirconia 10%, high temperature flux 4%, clay 8%, stabilizer 2%, and degumming agent 1%.
  • the soft porcelain includes the following raw materials in terms of weight percentage: calcium carbonate 50%, graphene 2%, silicon carbide whiskers 1%, clay 1%, AC foaming agent 1.5%, stabilizer 1%, processing aid 0.5%, lubricant 0.5%, high-strength resin 40%, mica 1%, corundum powder 1%, and colorant 0.5%.
  • the wear-resistant coating includes the following raw materials in terms of weight percentage: graphene 1%, silicon carbide whiskers 5%, corundum powder 4%, vermiculite 5%, kaolin 20%, flame retardant 10%, nano titanium dioxide 5 %, Sodium phosphate 15%, sodium silicate 20%, hydroxyethyl cellulose 5%, silicone acrylic emulsion 3%, and silica sol 7%.
  • the high-strength resin is modified by polyethylene resin, and the specific modification method is: adding 8% by mass of carbon nanotubes, silicon micropowder, and zinc oxide to the polyethylene resin, and then mixing them uniformly and extruding Granulation is obtained to obtain a high-strength resin.
  • the mass ratio of the carbon nanotubes, silicon fine powder, and zinc oxide is 4: 8: 3.
  • the stone tailings are granite and marble.
  • the stone tailings are first pretreated.
  • the pretreatment process is: crushing and grinding the stone tailings, and then adding citrate and sodium p-aminobenzenesulfonate for secondary grinding; adding citrate and p-amino Sodium besylate is 0.5% and 0.5% of stone tailings mass, respectively
  • the high temperature flux is calcined talc, diopside and fluorite.
  • the stabilizer is a lead salt composite stabilizer and liquid barium and cadmium.
  • Example 1 Compared with Example 1, the stone tailings in the foamed lightweight material layer are not pretreated.
  • Example 1 Compared with Example 1, the high-strength resin in the foamed lightweight material layer is not subjected to modification treatment.
  • the high-strength resin in the foamed lightweight material layer is modified by adding carbon nanotubes, silicon fine powder, and zinc oxide, which are 12% by mass.
  • the high-strength resin in the foamed lightweight material layer is modified by adding carbon nanotubes, silicon fine powder, and zinc oxide, which are 15% by mass.
  • the high-strength resin in the foamed lightweight material layer is modified by adding carbon nanotubes, silicon fine powder, and zinc oxide which are 18% by mass.
  • Example 2 Compared to Example 1, no abrasion resistant coating was applied.
  • Example 1 Compared with Example 1, the foamed lightweight material layer, soft porcelain, and abrasion-resistant coating do not contain graphene.
  • the lightweight, high-strength, and high-strength foamed ceramic decorative integrated board of the present invention has high compressive strength, flexural strength, and combustion level, and low thermal conductivity and resistance.
  • the number of grinding test revolutions indicates that the present invention adheres a high-toughness decorative surface layer made of soft porcelain and a layer of foamed lightweight material through compression molding, and then applies a wear-resistant coating on the surface of the high-toughness decorative surface layer.
  • Good toughness, light weight and high strength, flame retardant, heat preservation, waterproof impermeability and anti-aging effects are examples of the foamed ceramic decorative integrated board of the present invention.
  • pretreated stone tailings and high-strength resin can better improve the strength, toughness, and abrasion resistance of the decorative integrated board.
  • Example 1 and Comparative Examples 2-4 it can be seen from Example 1 and Comparative Examples 2-4 that the abrasion-resistant coating can reduce the thermal conductivity and thereby improve the thermal insulation effect.
  • Graphene and silicon carbide whiskers can better improve the strength, toughness, and abrasion resistance of decorative monolithic panels.
  • Radionuclide limit test ⁇ spectrometer system is used to measure the internal exposure index and external exposure index of the test sample. The test results are shown in Table 2.
  • Example 1 Example 2 Example 3 Example 4 Example 5 Internal exposure index 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 External exposure index 0.02 0.02 0.02 0.02 0.02 0.02 0.02

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Abstract

一种轻质高强高韧的发泡陶瓷装饰一体板，包括发泡轻质材料层、高韧装饰面层和耐磨涂层；发泡轻质材料层包括：石材尾矿、石墨烯、氧化锆、高温助熔剂、粘土、稳定剂和解胶剂；高韧装饰面层包括：AC发泡剂、稳定剂、碳酸钙、高强度树脂、加工助剂、润滑剂。耐磨涂层包括：石墨烯、碳化硅晶须、刚玉粉、蛭石、高岭土、阻燃剂、纳米二氧化钛、磷酸钠、硅酸钠、羟乙基纤维素、硅丙乳液和硅溶胶。该发泡陶瓷装饰一体板，将软瓷制作的高韧装饰面层与发泡轻质材料层通过压模粘结在一起，然后在高韧装饰面层表面涂覆耐磨涂层，具有韧性好、轻质高强、阻燃、保温、防水抗渗和抗老化的效果。

Description

一种轻质高强高韧的发泡陶瓷装饰一体板及其制备方法 技术领域
本发明涉及装饰材料领域，特别涉及一种轻质高强高韧的发泡陶瓷装饰一体板及其制备方法。
背景技术
目前市场上现有的建筑内外墙体表面装饰层材料主要为：瓷砖、花岗岩、大理石、聚乙烯类挤塑保温装饰板以及外墙涂料，其中瓷砖、花岗岩和大理石在生产过程中，大量燃烧煤矿资源，对环境污染破坏严重，瓷砖本身自重大，没有自保温功能，在施工安装过程中采用大量水泥砂浆湿法粘贴，工序复杂使用寿命短、易开裂易脱落，造成的安全隐患较大；花岗岩和大理石本身属于不可再生的矿产资源，在城市日益开发建设需求，大量开采过程中严重破坏生态环境，成品率利用率极低，造成尾矿垃圾难以得到有效利用处理，容易造成地质灾害。聚乙烯类挤塑保温装饰板因材料本身限制易老化使用寿命短、耐候性差、防火性能差，且一但发生火灾产生大量有毒烟气，导致对环境污染破坏极大；外墙涂料中，弹性涂料、有光涂料、水性金属漆和和花王涂料一般均能满足吸水量和不透水性的要求，有些涂料要与某些底涂配合使用才能达到要求，对于透气性来说弹性涂料难以达到要求。因此，研究一种质轻、耐阻燃、防水抗渗、不易老化和力学性能优良的应用于建筑内外墙体表面的装饰材料迫在眉睫。
软瓷是一种新型的节能低碳装饰材料，其作为墙面装饰材料，具有质轻、柔性好、外观造型多样、耐候性好等特点；其用作地面装饰材料，具有耐磨、防滑、脚感舒适等特点；施工简便快捷，比传统材料缩短工期，节约空间，节约成本，而且不易脱落。适用于外墙、内墙、地面等建筑装饰，特别适用于高层建筑外饰面工程、建筑外立面装饰工程、城市旧城改造外墙面材、外保温体系的饰面层及弧形墙、拱形柱等异性建筑的饰面工程。
另外，随着工业化、城镇化进程的加快，我国工业领域的资源消耗量将进一步扩大，因资源开采和利用带来的环境问题日益突出，同时由于资源的利用率不高，产生了大量的石材 尾矿。石材尾矿一般都是采用自然堆放的办法进行处理。不但占用农田，而且对自然生态环境造成极大破坏。合理实现石材尾矿的综合利用，可以有效补充资源，提高国内资源保障力度。
申请号为CN201610265638.7的发明专利公开了一种软瓷聚氨酯保温装饰复合板的制备方法，通过将柔性软瓷的制备直接在聚氨酯保温板上进行，使得复合板能够一次合成。该风复合板兼具了保温和装饰的效果，但是强度不高，适应范围较受限。申请号为CN201610959101.0的发明专利，公开了一种保温装饰一体化饰面砖及其制备方法，将软瓷饰面层与保温层间连接成一个整体，具有装饰与保温功能。但是，该饰面砖由浆料材料粘结软瓷饰面层与保温层，容易产生裂缝，且该饰面砖在强度、韧性方面仍需改善。
发明内容
本发明的发明目的之一是，针对上述问题，提供一种轻质高强高韧的发泡陶瓷装饰一体板，将软瓷制作的高韧装饰面层与发泡轻质材料层通过压模粘结在一起，然后在高韧装饰面层表面涂覆耐磨涂层，具有韧性好、轻质高强、阻燃、保温、防水抗渗和抗老化的效果。
为达到上述目的，本发明所采用的技术方案是：
一种轻质高强高韧的发泡陶瓷装饰一体板，包括发泡轻质材料层、高韧装饰面层和耐磨涂层；所述的高韧装饰面层由软瓷制作而成，与所述发泡轻质材料层通过压模粘结在一起，所述耐磨涂层涂覆在高韧装饰面层表面。
所述发泡轻质材料层按重量百分比计，包括以下原料：石材尾矿65～85％、石墨烯0.05～10％、氧化锆0.05～10％、高温助熔剂0.05～10％、粘土0.05～8％、稳定剂0.05～5％和解胶剂0.05～5％。
所述的软瓷按重量百分比计，包括以下原料：碳酸钙30～50％、石墨烯0.05～10％、碳化硅晶须0.05～5％、粘土0.05～10％、AC发泡剂0.05～5％、稳定剂0.05～10％、加工助剂0.05～5％、润滑剂0.05～10％、高强度树脂30～60％、云母1～10％、刚玉粉0.05～10％和色料0.05～5％。
所述耐磨涂层按重量百分比计，包括以下原料：石墨烯1～10％、碳化硅晶须0.05～5％、刚玉粉3～10％、蛭石5～20％、高岭土5～20％、阻燃剂3～10％、纳米二氧化钛1～10％、 磷酸钠5～15％、硅酸钠10～20％、羟乙基纤维素0.05～5％、硅丙乳液3～6％和硅溶胶5～10％。
优选的，所述的高强度树脂为聚乙烯树脂、环氧树脂、聚氯乙烯树脂中的一种或多种经过改性而成，具体改性方法为：选取聚乙烯树脂、环氧树脂、聚氯乙烯树脂的一种或多种混合得到混合树脂，然后向所述混合树脂中加入占其质量百分比为5～15％的纳米碳管、硅微粉和氧化锌，然后混合均匀，挤出造粒，得高强度树脂。
优选的，所述纳米碳管、硅微粉和氧化锌的质量比为1～5:3～10:1～5。
优选的，所述的石材尾矿为花岗岩、长石、石英、砂岩、玄武岩、辉绿岩、页岩、石灰岩和大理岩中的一种或多种。
优选的，所述石材尾矿先经过预处理，所述预处理过程为：将石材尾矿粉碎、研磨，然后加入柠檬酸盐和对氨基苯磺酸钠进行二次研磨；加入的柠檬酸盐和对氨基苯磺酸钠分别为石材尾矿质量的0.5～1％和0.1～1％
优选的，所述的高温助熔剂为煅烧滑石、生滑石、透辉石和萤石中的一种或多种。
优选的，所述的稳定剂为液体钡锌复合稳定剂、液体钙锌复合稳定剂、铅盐复合稳定剂、液体钡镉和液体钡镉锌复合稳定剂中的一种或多种。
优选的，所述的解胶剂为多元羧酸水溶性有机类材料。
本发明的另一发明目的是，提供一种轻质高强高韧的发泡陶瓷装饰一体板的制备方法，采用通过分步预制、二次粘结成型，制得具有高韧性、轻质、高强、隔音隔热保温、阻燃、防水抗渗、抗老化、安装轻便的轻质高强高韧性的发泡陶瓷装饰一体板。
为达到上述目的，本发明所采用的技术方案是：
一种轻质高强高韧的发泡陶瓷装饰一体板的制备方法，包括以下步骤：
S1、发泡轻质材料的制备：按照所述配方称取石墨烯与石材尾矿，混合、粉碎并粉磨，然后加入其它原料，混合均化0.5～4h，经过喷雾造粒处理，烘干，得到发泡轻质粉料。
S2、高韧装饰面层的制备：按照所述配方称取碳酸钙和石墨烯，混合、粉碎并粉磨，然后加入配方中的其它原料，然后进入高速旋转混合机混合均化0.5～3h，经过喷雾造粒处理，烘干，进入储蓄仓备用，得到高韧装饰面层原料。
S3、烧制成型：将所述发泡轻质粉料在900～1300℃高温下烧成0.5～5h，冷却后取出， 切割成型，得到发泡轻质材料层。
S4、二次粘结成型：将所述高韧装饰面层原料在压力为2～6MPa、加热温度为180～250℃、挤出速率为45～100r/min的条件下压膜、微发泡、挤出，并立即所述发泡轻质层在整面压力为0.5～1.0MPa状态下进行粘结冷却，形成高韧装饰面层；经打磨、抛光、切割成形，得到发泡陶瓷装饰一体板粗品。
S5、涂覆：按照所述配方称取原料制备耐磨涂覆液，并均匀涂覆在所述发泡陶瓷装饰一体板粗品的高韧装饰面层的表面，形成耐磨涂层，得到发泡陶瓷装饰一体板成品。
优选的，步骤S5中，先将磷酸钠和硅酸钠倒入容器中混合加热，温度控制在50～70℃；并不停的搅拌，并硅溶胶，使其充分混合，得粘结剂；然后按比例将石墨烯、碳化硅晶须、刚玉粉、蛭石、高岭土、阻燃剂、纳米二氧化钛和羟乙基纤维素混合，加入硅丙乳液，搅拌混合1～2h，得混合料；最后将粘结剂和混合料加入搅拌器中，混合搅拌1～5h，使其混合均匀，即得到耐磨涂覆液。
本发明具有以下有益效果：
1.本发明的轻质高强高韧的发泡陶瓷装饰一体板，包括发泡轻质材料层、高韧装饰面层和耐磨涂层；将软瓷制作的高韧装饰面层与发泡轻质材料层通过压模粘结在一起，然后在高韧装饰面层表面涂覆耐磨涂层，具有韧性好、轻质高强、阻燃、保温、防水抗渗和抗老化的效果。
发泡轻质材料层、高韧装饰面层和耐磨涂层均含有石墨烯，通过石墨烯高比表面积、高吸附力的作用，使石墨烯均匀分散在其他材料表面，使物料的物理性质趋于稳定，与配方中各个原料相互辅助起到了抗老化、抗腐蚀、隔热保温、隔音、防水抗渗、防火耐火、轻质高强的效果。在发泡轻质材料层中加入氧化锆、粘土、稳定剂和解胶剂，氧化锆的增韧机制有应力诱导相变增韧和微裂纹增韧。通过石墨烯的二维片层结构，加强石墨烯和解胶剂之间的相互作用，吸附了大量的氧化锆、粘土和稳定剂，形成致密的物理层，提高材料的阻燃性、防水性、保温性和力学性能。
在高韧装饰面层中除石墨烯和碳酸钙外，还添加了云母、刚玉粉和碳化硅晶须，通过石墨烯的二维片层结构，均匀穿插在结构中提高装饰面材料的力学性能和防水性。碳化硅晶须具有很高的断裂强度和弹性模量，能弹性地承受较大的应变而无永久变形，利用碳化硅增韧 的机制有晶须拔出、桥连和裂纹偏转提高材料的稳定性。两者协同作用，提高了的抗压强度和柔韧性。
高强度树脂通过加入纳米碳管、硅微粉和氧化锌改性，提高树脂的强度和韧性，从而改善高韧装饰面层的力学性能。纳米碳管、硅微粉、氧化锌和树脂各自起着独立的作用,同时又相互依存,树脂的力学性能较差,只有把它们结合起来,形成一个整体,才能有效地发挥它们自身的作用，提高树脂强度。纳米碳管、硅微粉和氧化锌作为骨架,其含量适当增加可以提高树脂的强度，但是随着含量增加,反而使树脂结构松弛,造成强度降低，因此应严格控制含量。
耐磨涂层加入石墨烯和蛭石，采用蛭石、石墨烯与纳米二氧化钛、碳化硅晶须配合作用，能大大提高耐磨涂覆液在韧装饰面层的附着力。同时，在高温条件下，涂层不起泡、不龟裂、不剥落，起到防水、防火、隔热保温、防腐防锈、抗老化、绝缘等作用，延长发泡陶瓷装饰一体板使用寿命。
2.本发明的轻质高强高韧的发泡陶瓷装饰一体板，石材尾矿活性较低，与其他材料的相容性较差，因此先经过预处理改性。经过改性的石材尾矿亲和性和活性提高，从而改善材料之间的粘结性能，赋予微晶玉石高温稳定性和抗裂性能。
3.本发明的轻质高强高韧的发泡陶瓷装饰一体板的制备方法，通过分步预制、二次粘结成型，制得具有高韧性、轻质高强、力学性能优良、隔音隔热保温、阻燃、防水抗渗、抗老化、抗腐蚀、安装轻便、低碳节能和绿色环保的轻质高强高韧的发泡陶瓷装饰一体板。
具体实施方式
实施例1：
一种轻质高强高韧的发泡陶瓷装饰一体板
包括发泡轻质材料层、高韧装饰面层和耐磨涂层；所述的高韧装饰面层由软瓷制作而成，与所述发泡轻质材料层通过压模粘结在一起，所述耐磨涂层涂覆在高韧装饰面层表面。
所述发泡轻质材料层按重量百分比计，包括以下原料：石材尾矿75％、石墨烯5％、氧化锆5％、高温助熔剂5％、粘土5％、稳定剂2％和解胶剂3％。
所述的软瓷按重量百分比计，包括以下原料：碳酸钙35％、石墨烯5％、碳化硅晶须2％、粘土3％、AC发泡剂2％、稳定剂3％、加工助剂1％、润滑剂2％、高强度树脂40％、云母 3％、刚玉粉2％和色料2％。
所述耐磨涂层按重量百分比计，包括以下原料：石墨烯5％、碳化硅晶须2％、刚玉粉5％、蛭石20％、高岭土10％、阻燃剂5％、纳米二氧化钛8％、磷酸钠10％、硅酸钠15％、羟乙基纤维素5％、硅丙乳液5％和硅溶胶10％。
所述的高强度树脂为聚乙烯树脂改性而成，具体改性方法为：向聚乙烯树脂中加入占其质量百分比为10％的纳米碳管、硅微粉和氧化锌，然后混合均匀，挤出造粒，得高强度树脂。所述纳米碳管、硅微粉和氧化锌的质量比为2:5:2。所述的石材尾矿为花岗岩。
所述石材尾矿先经过预处理，所述预处理过程为：将石材尾矿粉碎、研磨，然后加入柠檬酸盐和对氨基苯磺酸钠进行二次研磨；加入的柠檬酸盐和对氨基苯磺酸钠分别为石材尾矿质量的1％和0.5％。所述的高温助熔剂为煅烧滑石。所述的稳定剂为液体钡锌复合稳定剂。所述的解胶剂为多元羧酸水溶性有机类材料。
制备方法，包括以下步骤：
S1、发泡轻质材料的制备：按照所述配方称取石墨烯与石材尾矿，混合、粉碎并粉磨，然后加入其它原料，混合均化2h，经过喷雾造粒处理，烘干，得到发泡轻质粉料。
S2、高韧装饰面层的制备：按照所述配方称取碳酸钙和石墨烯，混合、粉碎并粉磨，然后加入配方中的其它原料，然后进入高速旋转混合机混合均化2h，经过喷雾造粒处理，烘干，进入储蓄仓备用，得到高韧装饰面层原料。
S3、烧制成型：将所述发泡轻质粉料在1200℃高温下烧成2h，冷却后取出，切割成型，得到发泡轻质材料层。
S4、二次粘结成型：将所述高韧装饰面层原料在压力为5MPa、加热温度为200℃、挤出速率为60r/min的条件下压膜、微发泡、挤出，并立即所述发泡轻质层在整面压力为1.0MPa状态下进行粘结冷却，形成高韧装饰面层；经打磨、抛光、切割成形，得到发泡陶瓷装饰一体板粗品。
S5、涂覆：按照所述配方称取原料制备耐磨涂覆液，并均匀涂覆在所述发泡陶瓷装饰一体板粗品的高韧装饰面层的表面，形成耐磨涂层，得到发泡陶瓷装饰一体板成品。
耐磨涂覆液的制备方法为：先将磷酸钠和硅酸钠倒入容器中混合加热，温度控制在60℃；并不停的搅拌，并硅溶胶，使其充分混合，得粘结剂；然后按比例将石墨烯、碳化硅晶须、 刚玉粉、蛭石、高岭土、阻燃剂、纳米二氧化钛和羟乙基纤维素混合，加入硅丙乳液，搅拌混合1.5h，得混合料；最后将粘结剂和混合料加入搅拌器中，混合搅拌3h，使其混合均匀，即得到耐磨涂覆液。
实施例2：
一种轻质高强高韧的发泡陶瓷装饰一体板
包括发泡轻质材料层、高韧装饰面层和耐磨涂层；所述的高韧装饰面层由软瓷制作而成，与所述发泡轻质材料层通过压模粘结在一起，所述耐磨涂层涂覆在高韧装饰面层表面。
所述发泡轻质材料层按重量百分比计，包括以下原料：石材尾矿85％、石墨烯5％、氧化锆3％、高温助熔剂2％、粘土3％、稳定剂1％和解胶剂1％。
所述的软瓷按重量百分比计，包括以下原料：碳酸钙40％、石墨烯5％、碳化硅晶须2％、粘土3％、AC发泡剂2％、稳定剂3％、加工助剂2％、润滑剂5％、高强度树脂30％、云母5％、刚玉粉2％和色料1％。
所述耐磨涂层按重量百分比计，包括以下原料：石墨烯5％、碳化硅晶须3％、刚玉粉8％、蛭石15％、高岭土15％、阻燃剂5％、纳米二氧化钛10％、磷酸钠15％、硅酸钠15％、羟乙基纤维素4％、硅丙乳液4％和硅溶胶6％。
所述的高强度树脂为聚乙烯树脂改性而成，具体改性方法为：向聚乙烯树脂中加入占其质量百分比为5％的纳米碳管、硅微粉和氧化锌，然后混合均匀，挤出造粒，得高强度树脂。所述纳米碳管、硅微粉和氧化锌的质量比为3:6:2。
所述的石材尾矿为长石、石英和页岩。所述石材尾矿先经过预处理，所述预处理过程为：将石材尾矿粉碎、研磨，然后加入柠檬酸盐和对氨基苯磺酸钠进行二次研磨；加入的柠檬酸盐和对氨基苯磺酸钠分别为石材尾矿质量的0.6％和0.2％。
所述的高温助熔剂为透辉石和萤石中。所述的稳定剂为液体钙锌复合稳定剂和液体钡镉锌复合稳定剂。
制备方法，包括以下步骤：
S1、发泡轻质材料的制备：按照所述配方称取石墨烯与石材尾矿，混合、粉碎并粉磨，然后加入其它原料，混合均化3h，经过喷雾造粒处理，烘干，得到发泡轻质粉料。
S2、高韧装饰面层的制备：按照所述配方称取碳酸钙和石墨烯，混合、粉碎并粉磨，然 后加入配方中的其它原料，然后进入高速旋转混合机混合均化3h，经过喷雾造粒处理，烘干，进入储蓄仓备用，得到高韧装饰面层原料。
S3、烧制成型：将所述发泡轻质粉料在1300℃高温下烧成0.5h，冷却后取出，切割成型，得到发泡轻质材料层。
S4、二次粘结成型：将所述高韧装饰面层原料在压力为6MPa、加热温度为250℃、挤出速率为100r/min的条件下压膜、微发泡、挤出，并立即所述发泡轻质层在整面压力为0.5MPa状态下进行粘结冷却，形成高韧装饰面层；经打磨、抛光、切割成形，得到发泡陶瓷装饰一体板粗品。
S5、涂覆：按照所述配方称取原料制备耐磨涂覆液，并均匀涂覆在所述发泡陶瓷装饰一体板粗品的高韧装饰面层的表面，形成耐磨涂层，得到发泡陶瓷装饰一体板成品。
耐磨涂覆液的制备方法为：先将磷酸钠和硅酸钠倒入容器中混合加热，温度控制在70℃；并不停的搅拌，并硅溶胶，使其充分混合，得粘结剂；然后按比例将石墨烯、碳化硅晶须、刚玉粉、蛭石、高岭土、阻燃剂、纳米二氧化钛和羟乙基纤维素混合，加入硅丙乳液，搅拌混合1h，得混合料；最后将粘结剂和混合料加入搅拌器中，混合搅拌4h，使其混合均匀，即得到耐磨涂覆液。
实施例3：
一种轻质高强高韧的发泡陶瓷装饰一体板
包括发泡轻质材料层、高韧装饰面层和耐磨涂层；所述的高韧装饰面层由软瓷制作而成，与所述发泡轻质材料层通过压模粘结在一起，所述耐磨涂层涂覆在高韧装饰面层表面。
所述发泡轻质材料层按重量百分比计，包括以下原料：石材尾矿65％、石墨烯10％、氧化锆10％、高温助熔剂4％、粘土8％、稳定剂2％和解胶剂1％。
所述的软瓷按重量百分比计，包括以下原料：碳酸钙50％、石墨烯2％、碳化硅晶须1％、粘土1％、AC发泡剂1.5％、稳定剂1％、加工助剂0.5％、润滑剂0.5％、高强度树脂40％、云母1％、刚玉粉1％和色料0.5％。
所述耐磨涂层按重量百分比计，包括以下原料：石墨烯1％、碳化硅晶须5％、刚玉粉4％、蛭石5％、高岭土20％、阻燃剂10％、纳米二氧化钛5％、磷酸钠15％、硅酸钠20％、羟乙基纤维素5％、硅丙乳液3％和硅溶胶7％。
所述的高强度树脂为聚乙烯树脂改性而成，具体改性方法为：向聚乙烯树脂中加入占其质量百分比为8％的纳米碳管、硅微粉和氧化锌，然后混合均匀，挤出造粒，得高强度树脂。所述纳米碳管、硅微粉和氧化锌的质量比为4:8:3。
所述的石材尾矿为花岗岩和大理岩。所述石材尾矿先经过预处理，所述预处理过程为：将石材尾矿粉碎、研磨，然后加入柠檬酸盐和对氨基苯磺酸钠进行二次研磨；加入的柠檬酸盐和对氨基苯磺酸钠分别为石材尾矿质量的0.5％和0.5％
所述的高温助熔剂为煅烧滑石、透辉石和萤石中。所述的稳定剂为铅盐复合稳定剂和液体钡镉。
制备方法同实施例1。
实施例4
一种轻质高强高韧的发泡陶瓷装饰一体板
与实施例1相比，所述发泡轻质材料层中的石材尾矿不经过预处理。
实施例5
一种轻质高强高韧的发泡陶瓷装饰一体板
与实施例1相比，所述发泡轻质材料层中的高强度树脂不经过改性处理。
实施例6
一种轻质高强高韧的发泡陶瓷装饰一体板
与实施例1相比，所述发泡轻质材料层中的高强度树脂通过加入占其质量百分比为12％的纳米碳管、硅微粉和氧化锌进行改性。
实施例7
一种轻质高强高韧的发泡陶瓷装饰一体板
与实施例1相比，所述发泡轻质材料层中的高强度树脂通过加入占其质量百分比为15％的纳米碳管、硅微粉和氧化锌进行改性。
对比例1
一种轻质高强高韧的发泡陶瓷装饰一体板
与实施例1相比，所述发泡轻质材料层中的高强度树脂通过加入占其质量百分比为18％的纳米碳管、硅微粉和氧化锌进行改性。
对比例2：
一种轻质高强高韧的发泡陶瓷装饰一体板
与实施例1相比，不涂覆耐磨涂层。
对比例3：
一种轻质高强高韧的发泡陶瓷装饰一体板
与实施例1相比，所述发泡轻质材料层、软瓷和耐磨涂层中均不含有石墨烯。
对比例4：
一种轻质高强高韧的发泡陶瓷装饰一体板
与实施例1相比，所述软瓷和耐磨涂层中均不含有碳化硅晶须。
性能测试：按实施例1-7和对比例1-4的制备方法各制备发泡轻质装饰一体板样品，制成30mm×20mm×20mm的式样，检测式样的抗压强度、抗折强度、燃烧等级、隔声量和导热系数，具体步骤参照GB/T 17657-2013，结果见表1。
表1实施例1-5和对比例1-3性能测试结果
Figure PCTCN2019101846-appb-000001
实施例1-5和表1可以看出，本发明的轻质高强高韧的发泡陶瓷装饰一体板，具有较高的抗压强度、抗折强度和燃烧等级，较低的导热系数和耐磨性测试转数，说明本发明将软瓷制作的高韧装饰面层与发泡轻质材料层通过压模粘结在一起，然后在高韧装饰面层表面涂覆耐磨涂层，具有韧性好、轻质高强、阻燃、保温、防水抗渗和抗老化的效果。
实施例4-5可以看出，经过预处理的石材尾矿和高强度树脂能够更好地改善装饰一体板的强度、韧性和耐磨性。
实施例1、6-7和对比例1可以看出，纳米碳管、硅微粉和氧化锌作为骨架,其含量适当增加可以提高树脂的强度，但是随着含量增加,反而使树脂结构松弛,造成强度降低，因此应严格控制含量，15％为最佳添加量。
实施例1和对比例2-4可以看出，耐磨涂层能够降低导热系数，从而改善保温效果。石墨烯和碳化硅晶须能够能够更好地改善装饰一体板的强度、韧性和耐磨性。
放射性核素限量测试：用γ谱仪系统测量检测样品的内照射指数和外照射指数，检测结果见表2。
表2放射性核素限量测试数据
  实施例1 实施例2 实施例3 实施例4 实施例5
内照射指数 0.01 0.01 0.01 0.01 0.01
外照射指数 0.02 0.02 0.02 0.02 0.02
表2可知：内照射指数和外照射指数越低，说明样品的辐射量小，对人体产生的辐射作用也越小。实施例1-5的内照射指数和外照射指数均比较低，说明本发明所制备的轻质高强高韧的发泡陶瓷装饰一体板的辐射量均比较低，满足市场需求，使用较安全。
上述说明是针对本发明较佳可行实施例的详细说明，但实施例并非用以限定本发明的专利申请范围，凡本发明所提示的技术精神下所完成的同等变化或修饰变更，均应属于本发明所涵盖专利范围。

Claims (9)

  1. 一种轻质高强高韧的发泡陶瓷装饰一体板，其特征在于：包括发泡轻质材料层、高韧装饰面层和耐磨涂层；所述的高韧装饰面层由软瓷制作而成，与所述发泡轻质材料层通过压模粘结在一起，所述耐磨涂层涂覆在高韧装饰面层表面；
    所述发泡轻质材料层按重量百分比计，包括以下原料：石材尾矿65～85％、石墨烯0.05～10％、氧化锆0.05～10％、高温助熔剂0.05～10％、粘土0.05～8％、稳定剂0.05～5％和解胶剂0.05～5％；
    所述的软瓷按重量百分比计，包括以下原料：碳酸钙30～50％、石墨烯0.05～10％、碳化硅晶须0.05～5％、粘土0.05～10％、AC发泡剂0.05～5％、稳定剂0.05～10％、加工助剂0.05～5％、润滑剂0.05～10％、高强度树脂30～60％、云母1～10％、刚玉粉0.05～10％和色料0.05～5％；
    所述的高强度树脂为聚乙烯树脂、环氧树脂、聚氯乙烯树脂中的一种或多种经过改性而成，具体改性方法为：选取聚乙烯树脂、环氧树脂、聚氯乙烯树脂的一种或多种混合得到混合树脂，然后向所述混合树脂中加入占其质量百分比为5～15％的纳米碳管、硅微粉和氧化锌，然后混合均匀，挤出造粒，得高强度树脂；
    所述耐磨涂层按重量百分比计，包括以下原料：石墨烯1～10％、碳化硅晶须0.05～5％、刚玉粉3～10％、蛭石5～20％、高岭土5～20％、阻燃剂3～10％、纳米二氧化钛1～10％、磷酸钠5～15％、硅酸钠10～20％、羟乙基纤维素0.05～5％、硅丙乳液3～6％和硅溶胶5～10％。
  2. 根据权利要求1所述的轻质高强高韧的发泡陶瓷装饰一体板，其特征在于：所述纳米碳管、硅微粉和氧化锌的质量比为1～5:3～10:1～5。
  3. 根据权利要求1所述的轻质高强高韧的发泡陶瓷装饰一体板，其特征在于：所述的石材尾矿为花岗岩、长石、石英、砂岩、玄武岩、辉绿岩、页岩、石灰岩和大理岩中的一种或多种。
  4. 根据权利要求1所述的轻质高强高韧的发泡陶瓷装饰一体板，其特征在于：所述石材尾矿先经过预处理，所述预处理过程为：将石材尾矿粉碎、研磨，然后加入柠檬酸盐和对氨基苯磺酸钠进行二次研磨；加入的柠檬酸盐和对氨基苯磺酸钠分别为石材尾矿质量的0.5～1％和0.1～1％
  5. 根据权利要求1所述的轻质高强高韧的发泡陶瓷装饰一体板，其特征在于：所述的高温助熔剂为煅烧滑石、生滑石、透辉石和萤石中的一种或多种。
  6. 根据权利要求1所述的轻质高强高韧的发泡陶瓷装饰一体板，其特征在于：所述的稳定剂为液体钡锌复合稳定剂、液体钙锌复合稳定剂、铅盐复合稳定剂、液体钡镉和液体钡镉锌复合稳定剂中的一种或多种。
  7. 根据权利要求1所述的轻质高强高韧的发泡陶瓷装饰一体板，其特征在于：所述的解胶剂为多元羧酸水溶性有机类材料。
  8. 根据权利要求1-7任意一项所述的一种轻质高强高韧的发泡陶瓷装饰一体板的制备方法，其特征在于：包括以下步骤：
    S1、发泡轻质材料的制备：按照所述配方称取石墨烯与石材尾矿，混合、粉碎并粉磨，然后加入其它原料，混合均化0.5～4h，经过喷雾造粒处理，烘干，得到发泡轻质粉料；
    S2、高韧装饰面层的制备：按照所述配方称取碳酸钙和石墨烯，混合、粉碎并粉磨，然后加入配方中的其它原料，然后进入高速旋转混合机混合均化0.5～3h，经过喷雾造粒处理，烘干，进入储蓄仓备用，得到高韧装饰面层原料；
    S3、烧制成型：将所述发泡轻质粉料在900～1300℃高温下烧成0.5～5h，冷却后取出，切割成型，得到发泡轻质材料层；
    S4、二次粘结成型：将所述高韧装饰面层原料通过压膜、微发泡、挤出，并立即所述发泡轻质层在整面压力为0.5～1.0MPa状态下进行粘结冷却，形成高韧装饰面层；经打磨、抛光、切割成形，得到发泡陶瓷装饰一体板粗品；
    S5、涂覆：按照所述配方称取原料制备耐磨涂覆液，并均匀涂覆在所述发泡陶瓷装饰一体板粗品的高韧装饰面层的表面，形成耐磨涂层，得到发泡陶瓷装饰一体板成品。
  9. 根据权利要求8所述的轻质高强高韧的发泡陶瓷装饰一体板的其制备方法，其特征在于：步骤S5中，先将磷酸钠和硅酸钠倒入容器中混合加热，温度控制在50～70℃；并不停的搅拌，并硅溶胶，使其充分混合，得粘结剂；然后按比例将石墨烯、碳化硅晶须、刚玉粉、蛭石、高岭土、阻燃剂、纳米二氧化钛和羟乙基纤维素混合，加入硅丙乳液，搅拌混合1～2h，得混合料；最后将粘结剂和混合料加入搅拌器中，混合搅拌1～5h，使其混合均匀，即得到耐磨涂覆液。
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