Ultra-white fabric, ultra-white luxury stone ceramic rock board and preparation method thereof

Abstract

The present invention belongs to the technical field of ceramic tile production and manufacturing, and particularly relates to an ultra-white fabric, an ultra-white luxury stone ceramic rock plate and a preparation method thereof. The mineral composition of the ultra-white fabric includes: by mass percentage, ultra-white potassium feldspar: 20-38%, ultra-white kaolin: 40-50%, ultra-white quartz: 1-8%, high expansion zirconium phosphorus frit 15-25%, ultra-white calcined talc 0.5-2.5%; wherein the chemical composition of the high expansion zirconium phosphorus frit includes: by mass percentage, SiO 2 :46~53%,Al 2 O 3 :12.5~16.0%,Fe 2 O 3 :0.01~0.1%, TiO 2 :0.01~0.1%, CaO: 10~20%, MgO: 2.0~5.0%, K 2 O: 3.0~6.0%, Na 2 O: 3.0~6.0%, ZrO 2 :6.0~8.0%, P 2 O 5 : 0.5~1.5%, loss on ignition: 0.5~1.0%. The present invention uses a specially customized ultra-white surface formula to achieve ultra-high whiteness that conventional glazes cannot achieve under the premise of low zirconium content, and the resulting product meets the radioactivity standard, realizing customized batch production of ultra-white luxury stone ceramic rock slab series products.

Description

Technical Field

[0001] The present invention belongs to the technical field of ceramic tile production and manufacturing, and in particular relates to an ultra-white fabric, an ultra-white luxury stone ceramic rock board and a preparation method thereof. Background Art

[0002] Luxury stone is a precious natural stone with unique texture, rich colors, bright colors, and high hardness. The combination of natural luxury stone's ever-changing natural texture and color makes the space effect more ductile, and each product is unique, giving it special and precious properties, which can push the beauty of high-end space to the extreme, and is widely used in high-end decoration and luxury goods. Luxury stone is not just a piece of stone, it is also a work of art. Each piece of natural luxury stone has a strong cultural atmosphere and unique artistic temperament, which can greatly improve the cultural taste of the building. The application can make the space high-end and luxurious, showing the owner's unique taste, and is deeply favored by people. However, the development, collection and transportation of natural luxury stone are difficult, and the resources are non-renewable, which makes the price of natural luxury stone high in the market, and the decoration cost is high, which cannot meet the needs of mass consumption. At the same time, natural luxury stone has micro-crack defects, which are easy to cause cracking during the secondary processing process, which also leads to certain limitations in its application occasions. Summary of the invention

[0003] In view of the above problems, the present invention provides an ultra-white fabric, an ultra-white luxury stone ceramic rock slab and a preparation method thereof. By using a specially customized ultra-white fabric formula, ultra-high whiteness that cannot be achieved by conventional glazes is achieved under the premise of low zirconium content, and the resulting product meets the radioactivity standards, thereby realizing customized batch production of ultra-white luxury stone ceramic rock slab series products.

[0004] In a first aspect, the present invention provides an ultra-white fabric. The mineral composition of the ultra-white fabric includes, by mass percentage, ultra-white potassium feldspar: 20-38%, ultra-white kaolin: 40-50%, ultra-white quartz: 1-8%, high expansion zirconium phosphorus frit 15-25%, ultra-white calcined talc 0.5-2.5%; wherein the chemical composition of the high expansion zirconium phosphorus frit includes, by mass percentage, SiO2: 46-53%, Al2O3: 12.5-16.0%, Fe2O3: 0.01-0.1%, TiO2: 0.01-0.1%, CaO: 10-20%, MgO: 2.0-5.0%, K2O: 3.0-6.0%, Na2O: 3.0-6.0%, ZrO2: 6.0-8.0%, P2O5: 0.5-1.5%, and ignition loss: 0.5-1.0%.

[0005] Preferably, the mineral composition of the high expansion zirconium-phosphorus frit includes, by mass percentage, ultra-white potassium feldspar: 25-32%, ultra-white sodium feldspar: 25-30%, calcite: 14-20%, dolomite: 8.0-13.5%, zirconium silicate: 8-12%, ultra-white calcined kaolin: 2-8%, and calcium phosphate: 0.5-2%.

[0006] In a second aspect, the present invention provides an ultra-white luxury stone ceramic rock plate. The ultra-white luxury stone ceramic rock plate comprises, from bottom to top, a common base material layer, an ultra-white fabric layer, an inkjet printed pattern layer, and a dry granular glaze layer, wherein the ultra-white fabric layer is formed by the ultra-white fabric.

[0007] In a third aspect, the present invention provides a method for preparing an ultra-white luxury stone ceramic rock plate. The preparation method comprises the following steps:

[0008] The common base material and the ultra-white fabric cloth are pressed and formed into a blank;

[0009] Inkjet printing a pattern on the surface of the blank;

[0010] Apply dry granular glaze on the surface of the blank after the inkjet printing pattern;

[0011] The glazed body of the Bugan particles is fired and polished to obtain the ultra-white luxury stone ceramic rock slab.

[0012] Preferably, the particle gradation of the ultra-white fabric includes: in terms of mass percentage, above 30 mesh: 12-20%, 30-60 mesh: ≥70%, 60-80 mesh: ≤8%, below 80 mesh: ≤6%.

[0013] Preferably, the chemical composition of the dry granular glaze includes, by mass percentage, SiO2: 52~58%, Al2O3: 8~13%, Fe2O3: 0.01~0.2%, TiO2: 0.01~0.2%, CaO: 10~15%, MgO: 0.5~2.5%, K2O: 2.0~8.0%, Na2O: 1.0~3.5%, ZnO: 5~12%, BaO: 0.5~5.0%, ZrO2: 0.01~1.0%, P2O5: 0.01~1.0%, and loss on ignition: 0.5~1.0%.

[0014] Preferably, the dry granular glaze is applied by pouring glaze; the specific gravity of the dry granular glaze is 1.50-1.55 g / cm 3 , glaze application amount is 1000~1300g / m 2 .

[0015] Preferably, the firing temperature is 1160-1200° C., and the firing period is 50-150 minutes.

[0016] Preferably, ordinary base material is firstly laid to form an ordinary base material layer, and then ultra-white fabric is laid on the surface of the ordinary base material layer to form an ultra-white fabric layer.

[0017] Preferably, the thickness of the ultra-white fabric layer is 0.5-3 mm.

[0018] Beneficial Effects

[0019] The ultra-white luxury stone ceramic rock slab series products described in the present invention have a moist, delicate and soft texture, and at the same time have high hardness and high wear resistance, excellent pollution resistance, can resist the erosion of time, maintain the bright natural luxury stone texture and color for a long time, and have a high-end decorative effect, and are durable. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] Figure 1 This is a picture of the glaze effect of the ultra-white luxury stone ceramic rock plate prepared in Example 1 after firing;

[0021] Figure 2 This is a picture of the glaze effect of the ceramic rock plate prepared in comparative example 1 after firing;

[0022] Figure 3 This is a picture of the glaze effect of the ceramic rock plate prepared in comparative example 2 after firing;

[0023] Figure 4 This is a picture of the glaze effect of the ceramic rock plate prepared in Example 3 after firing. DETAILED DESCRIPTION

[0024] The present invention is further described by the following embodiments, and it should be understood that the following embodiments are only used to illustrate the present invention, but not to limit the present invention. The following is an exemplary description of the preparation method of the ultra-white luxury stone ceramic rock board of the present invention.

[0025] Prepare a common base material. The chemical composition of the common base material is not limited, and a conventional ceramic base material can be used. For example, the chemical composition of the common base material includes, by mass percentage, SiO2: 60-66%, Al2O3: 20-25%, Fe2O3: 0.2-0.8%, TiO2: 0.1-0.5%, CaO: 0.2-4.0%, MgO: 0.2-2.0%, K2O: 2.0-4.0%, Na2O: 2.0-4.0%, and loss on ignition: 3.5-5.5%.

[0026] The ultra-white fabric is prepared. The mineral composition of the ultra-white fabric includes, by mass percentage, 20-38% ultra-white potassium feldspar, 40-50% ultra-white kaolin, 1-8% ultra-white quartz, 15-25% high expansion zirconium phosphorus frit, and 0.5-2.5% ultra-white calcined talc.

[0027] The introduction of ultra-white potassium feldspar with low impurity content into ultra-white fabrics can increase the whiteness of the fabric blank after firing. This is mainly because the ultra-white potassium feldspar raw material has very few Fe and Ti impurities, which will improve the whiteness of the ultra-white fabric. 2+ Ions are more easily oxidized to Fe in K2O-containing glass than in Na2O-containing glass. 3+ , but Fe 3+ The coloring ability of the ion is only equivalent to Fe 2+ The coloring ability of the ions is 1 / 15, so the K2O-containing glass formed by the introduction of ultra-white potassium feldspar is easier to decolorize than the Na2O-containing glass phase formed by ultra-white sodium feldspar, and the whiteness after firing is higher.

[0028] Ultra-white kaolin with good plasticity is used in ultra-white fabrics to meet the requirements of dry pressing and can also ensure that the semi-finished bricks have high dry strength and no surface cracking and delamination. The ultra-white kaolin has fewer impurities and a low content of coloring oxides such as iron and titanium. After being introduced into the fabric formula, it can effectively improve the whiteness of the fabric formula after firing. At the same time, the refractive index of the mullite phase generated by the ultra-white kaolin after firing is as high as 1.66~1.72, which has a large deviation from the glass phase, increasing the diffuse reflection intensity of the incident light on the surface of the body, further improving the whiteness of the ultra-white fabric after firing.

[0029] Introducing ultra-white quartz with less impurities into ultra-white fabrics can increase the whiteness of ultra-white fabrics after firing. This is mainly because the Fe and Ti impurities in the ultra-white quartz raw materials are very small, which will improve the whiteness of ultra-white fabrics.

[0030] The chemical composition of the high expansion zirconium-phosphorus frit includes, by mass percentage, SiO2: 46-53%, Al2O3: 12.5-16%, Fe2O3: 0.01-0.1%, TiO2: 0.01-0.1%, CaO: 10-20%, MgO: 2.0-5.0%, K2O: 3.0-6.0%, Na2O: 3.0-6.0%, ZrO2: 6.0-8.0%, P2O5: 0.5-1.5%, and loss on ignition: 0.5-1.0%.

[0031] The mineral composition of the high expansion zircon-phosphorus frit includes, by mass percentage, 25-32% of ultra-white potassium feldspar, 25-30% of ultra-white sodium feldspar, 14-20% of calcite, 8.0-13.5% of dolomite, 8-12% of zirconium silicate, 2-8% of ultra-white calcined kaolin, and 0.5-2% of calcium phosphate.

[0032] The high expansion zirconium phosphorus frit adopts calcite and dolomite, introduces high initial melting point CaO and MgO components, and does not introduce low initial melting point B2O3, ZnO and potassium carbonate and potassium nitrate components, which effectively improves the initial melting temperature of the high expansion zirconium phosphorus frit, and avoids defects such as glaze pinholes, green body sandwich and bulging caused by the low initial melting temperature of the frit. The high expansion zirconium phosphorus frit adopts ultra-white potassium feldspar, ultra-white sodium feldspar and ultra-white calcined kaolin with very few Fe and Ti impurities, which can effectively reduce the Fe2O3 and TiO2 components of the high expansion zirconium phosphorus frit, and after being introduced into the fabric formula, the whiteness of the fabric formula after firing can be effectively improved. The high expansion zirconium-phosphorus frit adopts zirconium silicate and calcium phosphate to introduce ZrO2 and P2O5 components. Under the low-temperature fast firing system of the rock plate product, the zircon dissolved in the glass phase will re-precipitate a zircon phase with a particle size close to the light wavelength (0.5μm) due to supersaturation; at the same time, the incompatibility between the asymmetric PO tetrahedron and the symmetric Si-O tetrahedron determines that phase separation is inevitable in the silicate glass phase, and there are both zircon crystals of appropriate particle size and glass phase bodies of appropriate particle size, which can increase the opacity and further improve the whiteness of the ultra-white fabric after firing.

[0033] The present invention adopts a high melting temperature and the presence of a high-strength flux with strong melting ability to make most of the finely milled zircon powder melt in the glass phase of the opalescent glaze, thereby preparing a high expansion zircon-phosphorus frit. In some embodiments, the raw materials are weighed according to the mineral composition of the high expansion zircon-phosphorus frit, mixed evenly, and melted at 1550-1650° C. for 2-4 hours to obtain a glass liquid; the glass liquid is then quenched and crushed to obtain the high expansion zircon-phosphorus frit.

[0034] High expansion zirconium phosphorus frit is introduced into the ultra-white fabric of the blank to increase the post-firing whiteness of the ultra-white fabric. This is mainly because the particle size of the zirconium component opacifier needs to be as small as possible, and the opacification effect is best when it is as small as the same order of magnitude as the wavelength of light (0.5μm). The so-called ultra-fine zircon powder or zirconium silicate obtained by mechanical processing cannot meet this requirement. Because any mechanical method is not easy to achieve this crushing standard, even if it is barely achieved, the production cost is also high. Under the low-temperature fast-firing system of the rock plate product, the zircon that has been dissolved in the glass phase will re-precipitate a zircon phase close to the particle size of the wavelength of light (0.5μm) due to supersaturation, achieving high opacity, thereby improving the post-firing whiteness of the ultra-white fabric. The frit introduces P2O5 components. The incompatibility between the asymmetric PO tetrahedron and the symmetric Si-O tetrahedron determines that phase separation is inevitable in the silicate glass phase. There are both zircon crystals of appropriate particle size and glass phase bodies of appropriate particle size, which can increase the opacity and further improve the whiteness of the ultra-white fabric after firing.

[0035] The introduction of ultra-white calcined talc with low impurity content into the ultra-white fabric of the blank can improve the whiteness of the ultra-white fabric. This is mainly because the ultra-white calcined talc raw material has very few Fe and Ti impurities, which will improve the whiteness of the ultra-white fabric. This is the basic factor. At the same time, whether in the glass phase or in the enstatite generated by the talc itself, Mg 2+ The coordination number of the ion is 6, and its ionic radius is 66 pm. 2+ The coordination number of the ion is close to the ionic radius (76 pm), so it can dissolve some Fe 2+ ions to improve whiteness. At the same time, talc and clay minerals can generate cordierite, which contains six-fold coordinated Mg 2+ In addition, there is also some six-fold coordinated trivalent Al 3+ ions, which are related to Fe 3+ The ions are similar in charge, ionic radius, and coordination number. It is no doubt that cordierite can also dissolve more Fe 2+ , Fe 3+ , which is another reason why super white burned talc improves the whiteness of fabrics.

[0036] The ultra-white fabric is prepared according to the mineral composition of the ultra-white fabric according to a conventional process. For example, after the various mineral components of the ultra-white fabric are evenly mixed, water and an additive are added, and the slurry is evenly obtained by ball milling. The slurry is sieved and aged, and then spray-dried to obtain the ultra-white fabric. The moisture content of the ultra-white fabric is about 7.5-8.5wt%.

[0037] The particle gradation of the ultra-white fabric includes: by mass percentage, 30 mesh and above: 12-20%, 30-60 mesh: ≥70%, 60-80 mesh: ≤8%, and below 80 mesh: ≤6%. The ultra-white fabric with the above particle gradation helps to improve the plasticity of the blank.

[0038] Ordinary base material and ultra-white fabric cloth are pressed and formed to obtain a blank.

[0039] For example, a layer of ordinary base material is firstly laid and then a layer of ultra-white fabric is laid in a second thin method. The ultra-white fabric layer thickness of the ultra-white fabric can be 0.5-3 mm. In some embodiments, the amount of ultra-white fabric is 1100-2000 g / m 2 .

[0040] The green body is dried. The drying temperature may be 100-150° C. The drying time may be 40-60 minutes. Preferably, the moisture content of the dried green body is controlled within 0.5wt%.

[0041] The pattern is printed by inkjet printing on the surface of the blank. The inkjet pattern can be printed by using an inkjet machine using ordinary ink. The texture and color of the inkjet pattern can be adaptively changed as needed.

[0042] After the inkjet printing pattern, a dry granular glaze is applied on the surface of the blank. The chemical composition of the dry granular glaze includes, by mass percentage, SiO2: 52-58%, Al2O3: 8-13%, Fe2O3: 0.01-0.2%, TiO2: 0.01-0.2%, CaO: 10-15%, MgO: 0.5-2.5%, K2O: 2.0-8.0%, Na2O: 1.0-3.5%, ZnO: 5-12%, BaO: 0.5-5.0%, ZrO2: 0.01-1.0%, P2O5: 0.01-1.0%, and loss on ignition: 0.5-1.0%.

[0043] In some embodiments, the mineral composition of the dry granular glaze includes, by mass percentage, potassium feldspar: 23~40%, sodium feldspar: 15~25%, wollastonite: 5~15%, burned talc: 1~6%, calcite: 5~15%, dolomite: 5~15%, zinc oxide: 5~12%, barium carbonate: 1.0~8.0%, zirconium silicate: 0.01~2.0%, and calcium phosphate: 0.01~2.0%.

[0044] The dry granule glaze can be applied by spraying or pouring. Preferably, the dry granule glaze is poured by bell jar.

[0045] In some embodiments, the specific gravity of the dry granular glaze is 1.50-1.55 g / cm 3 , glaze application amount is 1000~1300g / m 2 Controlling the glazing parameters of dry granular glazing within the above range can not only ensure the flatness of the glaze surface after firing and the quality of the glaze surface after polishing, but also present high transparency and fully display the color and texture of the inkjet pattern.

[0046] The glazed body is dried at high temperature at a temperature of 100-150°C.

[0047] Firing. Rapid firing in a roller kiln. For example, the maximum firing temperature is 1160~1200℃ and the firing cycle is 50~150 minutes.

[0048] Polishing and waxing. Edge grinding and grading. Packing and storage. Obtaining the ultra-white luxury stone ceramic rock slab.

[0049] The green body of the present invention belongs to feldspathic porcelain. The microstructure of feldspathic porcelain is usually composed of 45-65wt% glass phase, 10-20wt% mullite crystal, 10-30wt% residual quartz (including cristobalite), and a small amount of pores. The whiteness of the green body of this system is mainly related to the Fe and Ti impurities in the green body, and is related to the size of the refractive index difference between the crystal phase and the glass phase in the green body (the larger the difference, the higher the whiteness), and secondly to the amount of glass phase. The more glass phase, the lower the whiteness. In addition to the above factors, the high expansion zirconium-phosphorus frit of the present invention adopts zirconium silicate and calcium phosphate to introduce ZrO2 and P2O5 components. Under the low-temperature fast firing system of the rock plate product, the zircon dissolved in the glass phase will re-precipitate a zircon phase with a particle size close to the light wavelength (0.5μm) due to supersaturation; at the same time, the incompatibility between the asymmetric PO tetrahedron and the symmetric Si-O tetrahedron determines that phase separation is inevitable in the silicate glass phase, and there are both zircon crystals of appropriate particle size and glass phase bodies of appropriate particle size, which can increase the opacity and further improve the whiteness of the ultra-white fabric after firing.

[0050] The whiteness of the ultra-white luxury stone ceramic rock board described in the present invention can reach 82 degrees. During the research and development process, it was found that the use of conventional zirconium white glaze can certainly whiten the surface, but the whiteness of the rock board can only reach about 70 degrees. In order to further whiten, a higher proportion of ultra-white kaolin is introduced into the ultra-white fabric of the present invention, and a large number of mullite phases with high refractive index (refractive index 1.66~1.72) are formed after firing, and the refractive index deviation from the glass phase is large, which increases the diffuse reflection intensity of the incident light on the surface of the blank, thereby further improving the post-firing whiteness of the ultra-white fabric. In addition, the present invention uses ultra-white kaolin, ultra-white potassium feldspar, high-expansion zirconium phosphorus frit, ultra-white fired talc, and ultra-white quartz to prepare ultra-white fabrics, combined with inkjet printing technology and dry granular soft polishing technology, which can be used to produce ultra-white luxury stone ceramic rock boards with stone texture pattern decoration, which can broaden the application space of building ceramic products. The ultra-white luxury stone ceramic tiles fired through this process can highly restore the snow-white and warm texture of natural luxury stone. They have excellent pollution resistance, high hardness and high wear resistance, and are durable.

[0051] The following examples are further listed to illustrate the present invention in detail. It should also be understood that the following examples are only used to further illustrate the present invention and cannot be understood as limiting the scope of protection of the present invention. Some non-essential improvements and adjustments made by those skilled in the art based on the above content of the present invention belong to the scope of protection of the present invention. The specific process parameters and the like in the following examples are also only examples within a suitable range, that is, those skilled in the art can make a selection within a suitable range through the description herein, and are not limited to the specific values ​​​​exemplified below.

[0052] Example 1

[0053] The preparation method of the ultra-white luxury stone ceramic rock plate comprises the following steps:

[0054] Step 1: Lay out ordinary base material.

[0055] Step 2: After laying the ordinary base material, the ultra-white fabric is laid for the second time. The mineral composition of the ultra-white fabric includes: by mass percentage, ultra-white potassium feldspar 37%, ultra-white kaolin 42%, ultra-white quartz 2%, high expansion zirconium phosphorus frit 18%, ultra-white burned talc: 1%. The chemical composition of the high expansion zirconium phosphorus frit includes: by mass percentage, SiO2: 50.45%, Al2O3: 14.25%, Fe2O3: 0.08%, TiO2: 0.07%, CaO: 14.63%, MgO: 3.61%, K2O: 4.87%, Na2O: 4.24%, ZrO2: 6.23%, P2O5: 0.95%, ignition loss: 0.62%. The chemical composition of the ultra-white fabric includes, by mass percentage, SiO2: 63.34%, Al2O3: 21.34%, Fe2O3: 0.07%, TiO2: 0.07%, CaO: 2.75%, MgO: 1.08%, K2O: 3.51%, Na2O: 2.13%, ZrO2: 1.12%, P2O5: 0.17%, and loss on ignition: 4.42%.

[0056] Step 2: Pressing and forming to obtain a green body, and drying the green body.

[0057] Step 3: Use an inkjet printer to print the design pattern on the surface of the dried blank.

[0058] Step 4: Apply dry granular glaze on the surface of the body with the inkjet printed design pattern using a bell jar glaze. The chemical composition of the dry granular glaze includes: in mass percentage, SiO2: 55.35%, Al2O3: 11.5%, Fe2O3: 0.1%, TiO2: 0.05%, CaO: 12.5%, MgO: 2.0%, K2O: 4.55%, Na2O: 3.15%, ZnO: 7.2%, BaO: 1.5%, ZrO2: 0.8%, P2O5: 0.5%, loss on ignition: 0.8%. The specific gravity of the dry granular glaze is 1.53 g / cm 3 , glaze application amount is 1200 g / m 2 .

[0059] Step 5: After the dry granular glaze is applied, the body is dried at high temperature and then quickly fired in a roller kiln. The maximum firing temperature is 1180℃ and the firing cycle is 80 minutes.

[0060] Step 6: Polishing, waxing, edging, grading, and packaging for storage.

[0061] Example 1 Ultra-white luxury stone slab uses 82-degree ultra-white surface material to highly restore the bright color and unique texture of ultra-white luxury stone, and the glaze effect is Figure 1 .

[0062] Comparative Example 1

[0063] The method is basically the same as Example 1, except that ordinary high-zirconium fabric is used. The method for preparing the ceramic rock plate comprises the following steps:

[0064] Step 1: Lay out ordinary base material.

[0065] Step 2: After laying the ordinary base material, lay the ordinary high-zirconium fabric for the second thin method. The mineral composition of the ordinary high-zirconium fabric includes: by mass percentage, potassium feldspar 48.5%, sodium feldspar 13.5%, kaolin 23%, calcined alumina 7%, zirconium silicate 8%. The chemical composition of the ordinary high-zirconium fabric includes: by mass percentage, SiO2: 56.47%, Al2O3: 25.82%, Fe2O3: 0.31%, TiO2: 0.14%, CaO: 0.25%, MgO: 0.18%, K2O: 4.85%, Na2O: 2.95%, ZrO2: 5.17%, and the loss on ignition is 3.86%.

[0066] Step 2: Pressing and forming to obtain a green body, and drying the green body.

[0067] Step 3: Use an inkjet printer to print the design pattern on the surface of the dried blank.

[0068] Step 4: Apply dry granular glaze on the surface of the inkjet printed design pattern using a bell jar glaze. The chemical composition of the dry granular glaze includes: in mass percentage, SiO2: 55.35%, Al2O3: 11.5%, Fe2O3: 0.1%, TiO2: 0.05%, CaO: 12.5%, MgO: 2.0%, K2O: 4.55%, Na2O: 3.15%, ZnO: 7.2%, BaO: 1.5%, ZrO2: 0.8%, P2O5: 0.5%, loss on ignition: 0.8%. The specific gravity of the dry granular glaze is 1.53 g / cm 3 , glaze application amount is 1200 g / m 2 .

[0069] Step 5: After the dry granular glaze is applied, the body is dried at high temperature and then quickly fired in a roller kiln. The maximum firing temperature is 1180℃ and the firing cycle is 80 minutes.

[0070] Step 6: Polishing, waxing, edging, grading, and packaging for storage.

[0071] The ceramic rock plate of comparative example 1 uses ordinary high-zirconium fabric, and the whiteness after firing is only 70 degrees, which cannot restore the bright color and unique texture of the ultra-white luxury stone, and the glaze effect is Figure 2 .

[0072] Comparative Example 2

[0073] The method is basically the same as Example 1, except that the boron-containing low initial melting point zirconium-phosphorus frit is introduced into the ultra-white fabric. The method for preparing the ceramic rock plate comprises the following steps:

[0074] Step 1: Lay out ordinary base material.

[0075] Step 2: After laying the ordinary base material, a second thin method is used to lay the low melting point ultra-white fabric containing boron. The mineral composition of the ultra-white fabric containing low melting point contains: by mass percentage, ultra-white potassium feldspar 24%, ultra-white kaolin 52%, ultra-white quartz 8.5%, boron-containing low melting point zirconium-phosphorus frit 15%, and burnt talc 0.5%. The chemical composition of the boron-containing low melting point zirconium-phosphorus frit contains: by mass percentage, SiO2: 44.12%, Al2O3: 12.33%, Fe2O3: 0.1%, TiO2: 0.06%, CaO: 10.65%, MgO: 6.83%, K2O: 6.33%, Na2O: 8.67%, ZrO2: 7.54%, P2O5: 0.69%, B2O3: 1.95%, and ignition loss: 0.73%. The chemical composition of the ordinary boron-containing low initial melting point ultra-white fabric includes, by mass percentage, SiO2: 63.21%, Al2O3: 21.06%, Fe2O3: 0.05%, TiO2: 0.03%, CaO: 1.81%, MgO: 1.18%, K2O: 3.47%, Na2O: 2.27%, ZrO2: 1.13%, P2O5: 0.10%, B2O3: 0.29%, and loss on ignition 5.40%.

[0076] Step 2: Pressing and forming to obtain a green body, and drying the green body.

[0077] Step 3: Use an inkjet printer to print the design pattern on the surface of the dried blank.

[0078] Step 4: Apply dry granular glaze on the surface of the inkjet printed design pattern using a bell jar glaze. The chemical composition of the dry granular glaze includes: by mass percentage, SiO2: 55.35%, Al2O3: 11.5%, Fe2O3: 0.1%, TiO2: 0.05%, CaO: 12.5%, MgO: 2.0%, K2O: 4.55%, Na2O: 3.15%, ZnO: 7.2%, BaO: 1.5%, ZrO2: 0.8%, P2O5: 0.5%, loss on ignition: 0.8%. The specific gravity of the dry granular glaze is 1.53 g / cm 3 , glaze application amount is 1200 g / m 2 .

[0079] Step 5: After the dry granular glaze is applied, the body is dried at high temperature and then quickly fired in a roller kiln. The maximum firing temperature is 1180℃ and the firing cycle is 80 minutes.

[0080] Step 6: Polishing, waxing, edging, grading, and packaging for storage.

[0081] The ceramic rock plate of Comparative Example 2 has many pinholes on the glaze surface after firing due to the introduction of boron-containing low initial melting point zirconium-phosphorus frit, and the glaze effect is Figure 3 .

[0082] Comparative Example 3

[0083] The method is basically the same as Example 1, except that a low-plasticity ultra-white fabric is used. The method for preparing the ceramic rock plate comprises the following steps:

[0084] Step 1: Lay out ordinary base material.

[0085] Step 2: After the ordinary base material is laid, the low plasticity ultra-white fabric is laid again by a second thin method. The mineral composition of the low plasticity ultra-white fabric includes: by mass percentage, ultra-white potassium feldspar 40%, ultra-white kaolin 22%, ultra-white calcined kaolin 12%, ultra-white quartz 6%, high expansion zirconium phosphorus frit 18%, and burnt talc 2%. The chemical composition of the low plasticity ultra-white fabric includes: by mass percentage, SiO2: 64.43%, Al2O3: 21.47%, Fe2O3: 0.10%, TiO2: 0.12%, CaO: 2.81%, MgO: 1.42%, K2O: 3.56%, Na2O: 2.18%, ZrO2: 1.12%, P2O5: 0.17%, and ignition loss 2.62%.

[0086] Step 2: Pressing and forming to obtain a green body, and drying the green body.

[0087] Step 3: Use an inkjet printer to print the design pattern on the surface of the dried blank.

[0088] Step 4: Apply dry granular glaze on the surface of the inkjet printed design pattern using a bell jar glaze. The chemical composition of the dry granular glaze includes: by mass percentage, SiO2: 55.35%, Al2O3: 11.5%, Fe2O3: 0.1%, TiO2: 0.05%, CaO: 12.5%, MgO: 2.0%, K2O: 4.55%, Na2O: 3.15%, ZnO: 7.2%, BaO: 1.5%, ZrO2: 0.8%, P2O5: 0.5%, loss on ignition: 0.8%. The specific gravity of the dry granular glaze is 1.53 g / cm 3 , glaze application amount is 1200 g / m 2 .

[0089] Step 5: After the dry granular glaze is applied, the body is dried at high temperature and then quickly fired in a roller kiln. The maximum firing temperature is 1180℃ and the firing cycle is 80 minutes.

[0090] Step 6: Polishing, waxing, edging, grading, and packaging for storage.

[0091] The ceramic rock plate of Example 3 has low plasticity of ultra-white surface, and the glaze surface is prone to defects such as glaze peeling and glaze cracking after firing, and the glaze effect is Figure 4 .

Claims

1. An ultra-white luxury stone ceramic rock plate, characterized in that: The ultra-white luxury stone ceramic rock plate includes, from bottom to top, a common base material layer, an ultra-white fabric layer, an inkjet printing pattern layer, and a dry granular glaze layer, wherein the ultra-white fabric layer is formed by ultra-white fabric; the mineral composition of the ultra-white fabric includes: in terms of mass percentage, ultra-white potassium feldspar: 20-38%, ultra-white kaolin: 40-50%, ultra-white quartz: 1-8%, high expansion zirconium phosphorus frit 15-25%, and ultra-white calcined talc 0.5-2.5%; wherein the chemical composition of the high expansion zirconium phosphorus frit is The composition is: in mass percentage, SiO2: 46~53%, Al2O3: 12.5~16.0%, Fe2O3: 0.01~0.1%, TiO2: 0.01~0.1%, CaO: 10~20%, MgO: 2.0~5.0%, K2O: 3.0~6.0%, Na2O: 3.0~6.0%, ZrO2: 6.0~8.0%, P2O5: 0.5~1.5%, loss on ignition: 0.5~1.0%.

2. The ultra-white luxury stone ceramic rock plate according to claim 1 is characterized in that: The mineral composition of the high expansion zircon-phosphorus frit includes, by mass percentage, 25-32% of ultra-white potassium feldspar, 25-30% of ultra-white sodium feldspar, 14-20% of calcite, 8.0-13.5% of dolomite, 8-12% of zirconium silicate, 2-8% of ultra-white calcined kaolin, and 0.5-2% of calcium phosphate.

3. A method for preparing the ultra-white luxury stone ceramic rock plate according to claim 1 or 2, characterized in that: The preparation method comprises the following steps: The common base material and the ultra-white fabric cloth are pressed and formed into a blank; Inkjet printing a pattern on the surface of the blank; Apply dry granular glaze on the surface of the blank after the inkjet printing pattern; The glazed body of the Bugan particles is fired and polished to obtain the ultra-white luxury stone ceramic rock slab.

4. The preparation method according to claim 3, characterized in that: The particle gradation of the ultra-white fabric includes: in terms of mass percentage, above 30 mesh: 12-20%, 30-60 mesh: ≥70%, 60-80 mesh: ≤8%, below 80 mesh: ≤6%.

5. The preparation method according to claim 3, characterized in that: The chemical composition of the dry granular glaze includes, by mass percentage, SiO2: 52~58%, Al2O3: 8~13%, Fe2O3: 0.01~0.2%, TiO2: 0.01~0.2%, CaO: 10~15%, MgO: 0.5~2.5%, K2O: 2.0~8.0%, Na2O: 1.0~3.5%, ZnO: 5~12%, BaO: 0.5~5.0%, ZrO2: 0.01~1.0%, P2O5: 0.01~1.0%, and loss on ignition: 0.5~1.0%.

6. The preparation method according to claim 3, characterized in that: The dry granular glaze is applied by pouring glaze; the specific gravity of the dry granular glaze is 1.50-1.55 g / cm 3 , glaze application amount is 1000~1300g / m 2 .

7. The preparation method according to claim 3, characterized in that: The firing temperature is 1160~1200℃ and the firing cycle is 50~150 minutes.

8. The preparation method according to claim 3, characterized in that: Firstly, ordinary base material is laid to form an ordinary base material layer, and then ultra-white fabric is laid on the surface of the ordinary base material layer to form an ultra-white fabric layer.

9. The preparation method according to claim 3, characterized in that: The thickness of the ultra-white fabric layer is 0.5-3 mm.

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