Low-temperature fast-fired anti-cutting and anti-cracking rock plate and preparation method thereof

Abstract

The invention discloses a low-temperature fast-fired anti-cutting and anti-cracking rock plate. The rock plate comprises a green body layer, a ground coat layer, a decorative layer and a glazed layer which are sequentially arranged from bottom to top, the green body layer is prepared from the following raw materials in parts by mass: 2 to 4 parts of bentonite, 8 to 12 parts of bauxite, 3 to 5 parts of magnesia soil, 22 to 28 parts of waste brick powder, 8 to 12 parts of washed mud, 22 to 26 parts of bluestone and 21 to 25 parts of yellow sand; the waste brick powder is prepared from the following chemical components in percentage by mass: 65 to 66 percent of SiO2, 18 to 19 percent of Al2O3, 1.7 to 1.8 percent of Fe2O3, 0.50 to 1 percent of TiO2, 0.5 to 0.7 percent of CaO, 1.7 to 1.8 percent of MgO, 1.9 to 2 percent of K2O and 2 to 2.1 percent of Na2O; the bluestone is prepared from chemical components in percentage by mass as follows: 70%-71% of SiO2, 14%-14.5% of Al2O3, 3.0%-3.2% of Fe2O3, 0.2%-0.3% of TiO2, 1%-1.1% of CaO, 1.2%-1.4% of MgO, 1.3%-1.5% of K2O, 3.8%-4.0% of Na2O and the balance of ignition loss. According to the low-temperature fast-firing anti-cutting rock plate provided by the invention, on the premise of realizing low-temperature fast firing, the anti-cutting performance and the strength are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of architectural ceramics, and particularly relates to an anti-cutting and cracking rock slab with low-temperature and fast firing and a preparation method thereof. Background Art

[0002] A rock slab is a new type of ceramic material made from natural raw materials through the processes of slurry ball milling, drying and spray tower granulation, pressed by a hydraulic press, and fired in a kiln. As a new variety in the field of architectural ceramics, the rock slab has been warmly welcomed by the market due to its strong durability, good hardness, and strong decorative effect, and is widely used in fields such as household and kitchen boards.

[0003] Before use, the rock slab generally needs to be machined mechanically such as cutting, grinding, drilling, and chamfering. However, since the rock slab is a brittle material, according to incomplete statistics, there will be a cutting cracking probability of 10-20% during the mechanical processing of the rock slab products, which affects the later use of the products. To improve this shortcoming, the traditional technology adopts the method of high-temperature slow firing (the firing temperature exceeds 1250°C, and the firing cycle is 50-70 minutes), aiming to promote the development and growth of mullite crystals by high-temperature slow firing, increase the content of mullite crystals, and utilize the higher strength and thermal shock resistance of mullite crystals to enhance the anti-cutting and cracking performance of the rock slab. However, although the above method has an effect, the dispersion of mullite crystals in the glass phase of the rock slab is usually not good, which easily leads to local agglomeration of mullite crystals, and may instead exacerbate the generation of cutting cracks, resulting in limited improvement in the anti-cutting and cracking performance. In addition, the above technical means of high-temperature slow firing not only increases the calcination temperature but also prolongs the calcination time, which is not conducive to achieving low-temperature and fast firing, and is likely to reduce production energy consumption and improve the competitiveness of enterprises.

[0004] Since the anti-cutting and cracking performance of the rock slab mainly depends on the green body layer, in order to overcome the above defects, in the prior art, the raw materials of the green body layer are improved, aiming to reduce the firing temperature and firing cycle, and on the premise of achieving low-temperature and fast firing, increase the content of mullite formed during calcination and the dispersion of mullite crystals, thereby improving the anti-cutting and cracking performance of the rock slab. However, due to the differences in the selection of raw materials and the preparation process, the produced rock slabs still have technical defects such as high firing temperature, long firing time, and poor anti-cutting and cracking performance. Summary of the Invention

[0005] The purpose of the present invention is to provide an anti-cutting and cracking rock slab with low-temperature and fast firing. By improving the raw materials of the green body layer, it is beneficial to improve the anti-cutting and cracking performance and strength on the premise of reducing the firing temperature and firing cycle and achieving low-temperature and fast firing, so as to overcome the deficiencies in the prior art.

[0006] Another object of the present invention is to provide a preparation method of a cut-resistant and crack-resistant rock slab with low-temperature and fast firing, the firing temperature of which is as low as 1223 °C, the firing cycle is as low as 35-38 minutes, and the preparation method is simple and highly operable. On the premise of reducing the firing temperature and firing cycle to achieve low-temperature and fast firing, the cut-resistant and crack-resistant performance and strength can be improved to meet the actual use requirements.

[0007] To achieve this object, the present invention adopts the following technical solutions:

[0008] A cut-resistant and crack-resistant rock slab with low-temperature and fast firing, comprising a green body layer, a base glaze layer, a decorative layer and a polished glaze layer arranged in sequence from bottom to top;

[0009] Calculated by mass parts, the raw materials of the green body layer include: 2-4 parts of bentonite, 8-12 parts of bauxite, 3-5 parts of magnesia soil, 22-28 parts of waste brick powder, 8-12 parts of washed mud, 22-26 parts of bluestone and 21-25 parts of yellow sand;

[0010] Calculated by mass percentage, the chemical composition of the waste brick powder includes SiO2 65-66%, Al2O3 18-19%, Fe2O3 1.7-1.8%, TiO2 0.50-1%, CaO 0.5-0.7%, MgO 1.7-1.8%, K2O 1.9-2% and Na2O 2-2.1%;

[0011] Calculated by mass percentage, the chemical composition of the bluestone includes SiO2 70-71%, Al2O3 14-14.5%, Fe2O3 3.0-3.2%, TiO2 0.2-0.3%, CaO 1-1.1%, MgO 1.2-1.4%, K2O 1.3-1.5% and Na2O 3.8-4.0%, and the rest is loss on ignition, and the rest is loss on ignition.

[0012] Further, the particle size of the waste brick powder is ≤0.85 mm.

[0013] Further, calculated by mass percentage, the chemical composition of the magnesia soil includes SiO2 62-63%, Al2O3 5.7-5.8%, Fe2O3 1.6-1.7%, TiO2 0.1-0.2%, CaO 0.7-0.8%, MgO 19.5-20%, K2O 0.2-0.3% and Na2O 0.2-0.3%, and the rest is loss on ignition.

[0014] Further, calculated by mass percentage, the chemical composition of the bauxite includes 36 - 37% of SiO2, 46 - 47% of Al2O3, 1 - 1.2% of Fe2O3, 1.3 - 1.5% of TiO2, 0.4 - 0.5% of CaO, 0.2 - 0.3% of MgO, 2.6 - 2.8% of K2O, and 0.3 - 0.5% of Na2O, with the balance being loss on ignition.

[0015] Further, calculated by mass percentage, the chemical composition of the washed mud includes 50 - 53% of SiO2, 31 - 33% of Al2O3, 1.4 - 1.5% of Fe2O3, 0.1 - 0.2% of TiO2, 0.1 - 0.2% of CaO, 0.2 - 0.3% of MgO, 3 - 3.2% of K2O, and 0.3 - 0.4% of Na2O, with the balance being loss on ignition.

[0016] Further, calculated by mass percentage, the chemical composition of the bentonite includes 68 - 70% of SiO2, 14.5 - 15% of Al2O3, 0.8 - 0.9% of Fe2O3, 0.1 - 0.2% of TiO2, 1.4 - 1.6% of CaO, 1.5 - 1.6% of MgO, 2.9 - 3% of K2O, and 1.6 - 1.7% of Na2O, with the balance being loss on ignition.

[0017] Further, calculated by mass percentage, the chemical composition of the yellow sand includes 75 - 76% of SiO2, 10 - 11% of Al2O3, 0.5 - 1% of Fe2O3, 0.2 - 0.3% of TiO2, 0.3 - 0.4% of CaO, 0.2 - 0.3% of MgO, 1.8 - 2% of K2O, and 0.3 - 0.4% of Na2O, with the balance being loss on ignition.

[0018] A preparation method of a low - temperature and fast - firing anti - cutting and cracking rock slab for preparing the above - mentioned low - temperature and fast - firing anti - cutting and cracking rock slab, comprising the following steps:

[0019] A. After uniformly mixing the formula amounts of bentonite, bauxite, magnesia soil, waste brick powder, washed mud, bluestone, and yellow sand, adding water for ball - milling and sieving to obtain a slurry; spray - granulating the slurry to obtain a green body; pressing and forming the green body, and drying to obtain a green body layer; wherein, the fineness of the ball - milling is 325 - mesh sieve, and by mass percentage, the screen residue is 1.3 - 1.8%;

[0020] B. Applying a base glaze on the surface of the green body layer to obtain a base glaze layer;

[0021] C. Printing color ink on the surface of the base glaze layer according to a preset pattern to obtain a decorative layer;

[0022] D. Applying a polished glaze on the surface of the decorative layer to obtain a polished glaze layer;

[0023] E. After drying, it is fired in a kiln to obtain a rock slab resistant to cutting and cracking; wherein, the firing temperature of the rock slab resistant to cutting and cracking is ≤1223 °C, and the firing cycle is 35 - 38 min.

[0024] Further, in step A, the specific method of sieving is as follows: the raw materials of the green body layer after being ball-milled with water are filtered successively through a 40-mesh sieve, a 60-mesh sieve, and an 80-mesh sieve once, and then filtered through a 90-mesh sieve twice.

[0025] Further, in step E, the firing curve of the rock slab resistant to cutting and cracking includes a preheating section, a pre-temperature section, a medium-temperature section, a high-temperature section, a transition section, a rapid cooling section, and a slow cooling section;

[0026] The top temperature of the preheating section rises from room temperature to 854 °C, and the bottom temperature rises from room temperature to 841 °C, taking 5 - 5.4 min;

[0027] The top temperature of the pre-temperature section rises from 854 °C to 1080 °C, and the bottom temperature rises from 841 °C to 1090 °C, taking 5.1 - 5.7 min;

[0028] The top temperature of the medium-temperature section rises from 1080 °C to 1194 °C, and the bottom temperature rises from 1090 °C to 1205 °C, taking 5.5 - 5.8 min;

[0029] The top temperature of the high-temperature section rises from 1194 °C to 1204 °C, and the bottom temperature rises from 1205 °C to 1223 °C, taking 4.5 - 5 min;

[0030] The top temperature of the transition section drops from 1204 °C to 950 °C, and the bottom temperature drops from 1223 °C to 950 °C, taking 2 - 2.1 min;

[0031] The top temperature of the rapid cooling section drops from 950 °C to 584 °C, and the bottom temperature drops from 950 °C to 586 °C, taking 2 - 2.5 min;

[0032] The top temperature of the slow cooling section drops from 584 °C to 97 °C, and the bottom temperature drops from 586 °C to 97 °C, taking 11 - 11.6 min.

[0033] The technical solution provided by the present invention may include the following beneficial effects:

[0034] 1. In this technical solution, a eutectic K2O-Na2O-MgO-CaO quaternary composite flux is generated through the combined action of magnesian soil, waste brick powder, and bluestone. The above quaternary composite flux can cause the liquid phase to form in the green body layer in advance at a lower temperature. Due to the viscous flow and surface tension of the liquid phase, it can fill the voids inside the green body layer in advance, promote particle rearrangement, move closer to each other, and bond to form a whole. In addition, the basic oxides gradually enter the liquid phase, making the amount of liquid phase generated under the action of the quaternary composite flux gradually increase, and gradually appear in the green body layer in a stepped manner, and gradually dissolve other substances, resulting in the densification of the green body layer, which is beneficial to the purpose of reducing the firing temperature and shortening the firing cycle of the rock slab. In addition, the waste brick powder is a clinker that has been fired. When the clinker is added to the raw materials composed of other raw materials, it can promote the fast firing of the green body layer, further reduce the production energy consumption of the rock slab, and thus effectively promote the rapid firing of the rock slab and shorten the firing cycle. That is, through the above-mentioned multiple effects, the firing temperature of the rock slab is as low as 1223 °C, and the firing cycle is reduced to 35 - 38 min, achieving the purpose of reducing the firing temperature and shortening the firing cycle.

[0035] 2. The waste brick powder not only contains a glass phase but also contains mullite crystals. Through scanning electron microscopy observation and phase location analysis, it can be clearly observed that the mullite crystals are interspersed in the glass phase. In addition, the chemical components of the waste brick powder all include Al2O3 and SiO2, and the content of SiO2 in the waste brick powder is 65 - 66%, and the content of Al2O3 is 18 - 19%, belonging to the category of medium-aluminum and medium-silica raw materials (referring to raw materials with an Al2O3 content of 13 - 20% and an SiO2 content of 65 - 75% calculated by mass percentage). The above appropriate silicon-aluminum content is beneficial to promoting the uniform precipitation and growth of mullite crystals formed by the reaction of Al2O3 and SiO2 in the waste brick powder in the glass phase. Therefore, when adding waste brick powder to the raw materials of the green body layer, it can effectively improve the dispersibility of mullite crystals in the glass phase. In addition, the waste brick powder itself has gone through multiple processes such as mixing, ball milling, firing, and crushing, and when the raw materials of the green body layer are used, the raw materials of the green body layer generally need to go through the above processes again, further optimizing the dispersibility of each phase in the waste brick powder and further promoting the uniform dispersion of mullite crystals in the glass phase.

[0036] 3. The chemical components of bluestone include Al2O3 and SiO2, and the main mineral component of existing bluestone is albite. Al2O3 and SiO2 in albite can react to form mullite during calcination. Therefore, Al2O3 and SiO2 in bluestone react to form mullite. In addition, bluestone belongs to the category of medium-aluminum and medium-silica raw materials. The above appropriate silicon-aluminum content can promote the uniform precipitation and growth of mullite crystals formed by the reaction of Al2O3 and SiO2 in bluestone in the glass phase. Detailed implementation mode

[0037] This technical solution provides an anti-cutting and cracking rock slab with low-temperature and fast firing, which includes a green body layer, a base glaze layer, a decorative layer, and a polished glaze layer arranged in sequence from bottom to top;

[0038] Calculated by mass parts, the raw materials of the green body layer include: 2-4 parts of bentonite, 8-12 parts of bauxite, 3-5 parts of magnesia soil, 22-28 parts of waste brick powder, 8-12 parts of washed mud, 22-26 parts of bluestone, and 21-25 parts of yellow sand;

[0039] Calculated by mass percentage, the chemical composition of the waste brick powder includes SiO2 65-66%, Al2O3 18-19%, Fe2O3 1.7-1.8%, TiO2 0.50-1%, CaO 0.5-0.7%, MgO 1.7-1.8%, K2O 1.9-2%, and Na2O 2-2.1%;

[0040] Calculated by mass percentage, the chemical composition of the bluestone includes SiO2 70-71%, Al2O3 14-14.5%, Fe2O3 3.0-3.2%, TiO2 0.2-0.3%, CaO 1-1.1%, MgO 1.2-1.4%, K2O 1.3-1.5%, and Na2O 3.8-4.0%, and the rest is loss on ignition.

[0041] In order to solve the technical problems of high firing temperature, long firing time, and poor anti-cutting and cracking performance of rock slabs in the prior art, this technical solution proposes an anti-cutting and cracking rock slab. By optimizing the raw materials of the green body layer, the firing temperature of the rock slab is as low as 1223°C, and the firing cycle is as low as 35-38 minutes. Moreover, it has high strength and anti-cutting and cracking performance, enabling the rock slab to achieve low-temperature and fast firing, reduce production energy consumption, and improve the anti-cutting and cracking performance and strength to meet the actual use requirements.

[0042] Specifically, the raw materials of the green body layer include bentonite, bauxite, magnesian soil, waste brick powder, washed mud, bluestone and yellow sand. Among them, the mineral composition of the magnesian soil is mainly talc, which can introduce magnesium oxide into the formulation system. The chemical compositions of the waste brick powder and the bluestone both include potassium oxide, sodium oxide, magnesium oxide and calcium oxide. Therefore, the above raw materials can also introduce potassium oxide, sodium oxide, magnesium oxide and calcium oxide into the formulation system. Therefore, in this technical solution, a eutectic K2O-Na2O-MgO-CaO quaternary composite flux is generated through the combined action of these three raw materials, namely, the magnesian soil, the waste brick powder and the bluestone. The above quaternary composite flux can enable the green body layer to form a liquid phase in advance at a lower temperature. Due to the viscous flow and surface tension of the liquid phase, it can fill the voids inside the green body layer in advance, promote particle rearrangement, move closer to each other and bond to form a whole. In addition, the alkaline oxides gradually enter the liquid phase, making the amount of the liquid phase generated under the action of the quaternary composite flux gradually increase, and gradually appear in the green body layer in a stepped manner, and gradually dissolve other substances, resulting in the green body layer becoming more dense, which is conducive to reducing the firing temperature and shortening the firing cycle of the rock slab. In addition, the waste brick powder is a clinker that has been fired. When the clinker is added to the raw materials composed of other raw materials, it can promote the fast firing of the green body layer, further reduce the production energy consumption of the rock slab, and thus effectively promote the rapid firing of the rock slab and shorten the firing cycle. That is, through the above multi-faceted effects of this application, the firing temperature of the rock slab is as low as 1223 °C, and the firing cycle is reduced to 35-38 min, achieving the purpose of reducing the firing temperature and shortening the firing cycle.

[0043] Secondly, the waste brick powder not only contains a glass phase but also contains mullite crystals. Through scanning electron microscope observation and phase localization analysis, it can be clearly observed that the mullite crystals are interspersed in the glass phase. In addition, the chemical compositions of the waste brick powder both include Al2O3 and SiO2, and the content of SiO2 in the waste brick powder is 65-66%, and the content of Al2O3 is 18-19%, belonging to the category of medium-aluminum and medium-silicon raw materials (referring to raw materials with a mass percentage of Al2O3 of 13-20% and a content of SiO2 of 65-75%). The above appropriate silicon-aluminum content is conducive to promoting the uniform precipitation and growth of mullite crystals formed by the reaction of Al2O3 and SiO2 in the waste brick powder in the glass phase. Therefore, when the waste brick powder is added to the raw materials of the green body layer, the dispersibility of the mullite crystals in the glass phase can be effectively improved. In addition, the waste brick powder itself has gone through multiple processes such as mixing, ball milling, firing and crushing. And when the raw materials of the green body layer are used, the raw materials of the green body layer generally need to go through the above processes again, further optimizing the dispersibility of each phase in the waste brick powder and further promoting the uniform dispersion of the mullite crystals in the glass phase.

[0044] In addition, the chemical composition of bluestone includes Al2O3 and SiO2, and the main mineral component in the existing bluestone is albite. Al2O3 and SiO2 in albite can react to form mullite during the calcination process. Therefore, Al2O3 and SiO2 in bluestone react to form mullite. In addition, bluestone belongs to the category of medium-aluminum and medium-silica raw materials. The above-mentioned moderate silicon-aluminum content can promote the uniform precipitation and growth of mullite crystals formed by the reaction of Al2O3 and SiO2 in bluestone in the glass phase.

[0045] Therefore, through the above-mentioned multi-faceted effects of this technical solution, the mullite crystals in the green body layer are uniformly dispersed in the glass phase, which not only effectively reduces the stress concentration points (i.e., potential defect areas) in the glass phase, but also greatly hinders the cracking tendency of the glass phase, thereby significantly improving the anti-cutting crack performance of the rock slab. In addition, the uniform distribution of mullite crystals also significantly improves the thermal stability of the material, which is beneficial for the rock slab to better cope with thermal stress during the temperature change process, reduces the crack risk caused by uneven thermal expansion and contraction, and is also beneficial for improving the anti-cutting crack performance.

[0046] Furthermore, in the existing K2O and Na2O flux systems, when the calcination temperature reaches before the eutectic point, the amount of liquid phase that appears is very small. However, when the calcination temperature reaches the eutectic point, a large amount of liquid phase will immediately appear and rapidly increase with the increase of temperature. The rapid appearance of a large amount of liquid phase may make the stress distribution inside the green body layer uneven, affecting the anti-cutting crack performance of the rock slab. In the green body layer of this technical solution, due to the use of a quaternary composite flux of K2O-Na2O-MgO-CaO, the liquid phase generated during the melting of the raw materials is in a stepped shape, and it is a continuous stepped shape, resulting in the green body layer being more densified, which is also beneficial for improving the anti-cutting crack performance of the rock slab.

[0047] In summary, this technical solution effectively improves the anti-cutting crack performance of the rock slab by enhancing the dispersion of mullite crystals in the glass phase and the densification of the green body layer.

[0048] Again, due to its high strength and good thermal stability, when mullite crystals are evenly distributed inside the rock slab, they can effectively enhance the internal structure of the rock slab, thereby improving the overall strength. At the same time, by enhancing the densification of the green body layer, pores and defects can be reduced, and the structural integrity of the material can be improved, which is also an important factor in enhancing the strength of the rock slab. In addition, the two raw materials of waste brick powder and bluestone are rich in SiO2 and Al2O3, which is beneficial for promoting the formation of more mullite crystals, thereby further strengthening the overall strength of the rock slab.

[0049] Furthermore, the raw materials of the green body layer also include bentonite, bauxite, washed mud, and yellow sand. Among them, bentonite can tightly combine with other raw material particles to form a stable bonding structure, which has a positive effect on improving the strength of the rock slab; bauxite also helps to improve the strength of the rock slab due to its high-hardness alumina component. The washed mud has a more compact internal structure and enhanced bonding force between particles after purification, which also contributes to the improvement of the rock slab strength. Yellow sand is added to the formula as an aggregate, which can increase the skeleton support of the rock slab and further enhance its strength.

[0050] In summary, through the comprehensive exertion of various effects, this technical solution effectively improves the overall strength of the rock slab. It should be noted that yellow sand has a low cost and high whiteness, which is beneficial to improving the appearance quality of the rock slab on the premise of reducing product costs. In addition, washed mud and bentonite are conducive to the forming and shape retention of the green body layer, thereby reducing the waste brick rate of the calcined finished product.

[0051] Finally, calculated by mass parts, the raw materials of the green body layer include: 2 - 4 parts of bentonite, 8 - 12 parts of bauxite, 3 - 5 parts of magnesia soil, 22 - 28 parts of waste brick powder, 8 - 12 parts of washed mud, 22 - 26 parts of bluestone, and 21 - 25 parts of yellow sand. By limiting the components in the raw materials of the green body layer, it is beneficial for each raw material to give full play to its own advantages, thereby ensuring the performance of the rock slab. It should be noted that the main mineral component of bauxite is diaspore. If the addition amount of bauxite > 12 parts, it will lead to a relatively large amount of diaspore in the formula system, and the diaspore mineral will decompose to produce corundum α-Al2O3 during the firing process, and the reaction activity of corundum is low, making it difficult to form a uniform phase with other raw materials in the formula, thus affecting the anti-cutting and cracking performance; if the addition amount of bauxite < 8 parts, it will lead to a limited amount of introduced high-hardness aluminum oxide, resulting in a decrease in the strength of the rock slab and making it prone to softening during the calcination process. In addition, the main mineral component of yellow sand is free quartz. If the addition amount of yellow sand > 25 parts, it will lead to too much free quartz in the formula system, and free quartz, as a relatively sensitive crystal, is prone to phase transformation and volume change during the cooling process of the rock slab, thereby generating microcracks and affecting the anti-cutting and cracking performance; if the addition amount of yellow sand < 22 parts, it will result in a higher cost and a decrease in the whiteness of the product.

[0052] Preferably, calculated by mass percentage, the chemical composition of the bluestone includes SiO2 70.65%, Al2O3 14.30%, Fe2O3 3.16%, TiO2 0.28%, CaO 1.05%, MgO 1.29%, K2O 1.36%, Na2O 3.92%, and the rest is loss on ignition;

[0053] Calculated by mass percentage, the chemical composition of the waste brick powder includes SiO2 65.67%, Al2O3

[0054] 18.50%, Fe2O3 1.75%, TiO2 0.50%, CaO 0.62%, MgO 1.77%, K2O 1.92%, Na2O 2.09%, and the rest is loss on ignition.

[0055] Further, the particle size of the waste brick powder is ≤ 0.85 mm.

[0056] By limiting the particle size of the waste brick powder, it is not only beneficial to improve its utilization rate, but also beneficial to further optimize the dispersibility of each phase in the waste brick powder, further promoting the uniform dispersion of mullite crystals in the glass phase and further improving the anti-cutting and cracking performance of the rock slab. In addition, it can also ensure that the waste brick powder can better fill the micro-pores of the green body layer, enhance the density and strength of the rock slab, and is also beneficial to improving the anti-cutting and cracking performance of the rock slab.

[0057] Further, calculated by mass percentage, the chemical composition of the magnesian soil includes SiO2 62 - 63%, Al2O3 5.7 - 5.8%, Fe2O3 1.6 - 1.7%, TiO2 0.1 - 0.2%, CaO 0.7 - 0.8%, MgO 19.5 - 20%, K2O 0.2 - 0.3% and Na2O 0.2 - 0.3%, and the rest is loss on ignition.

[0058] This technical solution preferably adds magnesian soil with a CaO content of 0.7 - 0.8%, an MgO content of 19.5 - 20%, a K2O content of 0.2 - 0.3%, and an Na2O content of 0.2 - 0.3% calculated by mass percentage to the raw materials of the green body layer, which is beneficial to increasing the content of fluxes in the formulation system on the premise of avoiding excessive fluxes in the formulation causing the green body layer to be prone to softening and deformation during firing, so as to achieve the purpose of reducing the firing temperature and shortening the firing cycle. At the same time, the SiO2 content in the magnesian soil is 62 - 63% and the Al2O3 content is 5.7 - 5.8%, which is beneficial to increasing the content of silicon and aluminum in the formulation, thereby facilitating the formation of more silicate crystals and further enhancing the overall strength of the rock slab. It should be noted that the mineral composition of the magnesian soil is mainly talc and free quartz, etc., and the component silicon dioxide in the magnesian soil mainly exists in the form of free quartz, and free quartz is difficult to react with other components. Therefore, adding magnesian soil to the formulation does not tend to generate mullite crystals.

[0059] Preferably, calculated by mass percentage, the chemical composition of the magnesian soil includes SiO2 62.585%, Al2O3 5.79%, Fe2O3 1.615%, TiO2 0.13%, CaO 0.79%, MgO 19.5%, K2O 0.25%, Na2O 0.245%, and the rest is loss on ignition.

[0060] Further explanation, calculated by mass percentage, the chemical composition of the bauxite includes SiO2 36 - 37%, Al2O3 46 - 47%, Fe2O3 1 - 1.2%, TiO2 1.3 - 1.5%, CaO 0.4 - 0.5%, MgO 0.2 - 0.3%, K2O 2.6 - 2.8% and Na2O 0.3 - 0.5%, and the rest is loss on ignition.

[0061] This technical solution preferably adds bauxite with a SiO2 content of 36 - 37% and an Al2O3 content of 46 - 47% calculated by mass percentage to the raw materials of the green body layer, which is beneficial to increasing the content of silicon and aluminum in the formula, thereby improving the strength of the rock slab.

[0062] Preferably, calculated by mass percentage, the chemical composition of the bauxite includes SiO2 36.45%, Al2O3 46.13%, Fe2O3 1.02%, TiO2 1.33%, CaO 0.40%, MgO 0.22%, K2O 2.74%, Na2O 0.30%.

[0063] Further explanation, calculated by mass percentage, the chemical composition of the washed mud includes SiO2 50 - 53%, Al2O3 31 - 33%, Fe2O3 1.4 - 1.5%, TiO2 0.1 - 0.2%, CaO 0.1 - 0.2%, MgO 0.2 - 0.3%, K2O 3 - 3.2% and Na2O 0.3 - 0.4%, and the rest is loss on ignition.

[0064] This technical solution preferably adds SiO2 with a content of 50 - 53% and Al2O3 with a content of 31 - 33% calculated by mass percentage to the raw materials of the green body layer, which is beneficial to the reaction of SiO2 and Al2O3 in the washed mud to form mullite during calcination, increasing the content of mullite and its distribution in the glass phase, thereby improving the anti - cutting and cracking performance and strength. It should be noted that the main mineral component of the washed mud is kaolinite.

[0065] Preferably, calculated by mass percentage, the chemical components of the washed mud include 52.27% of SiO2, 32.5% of Al2O3, 1.41% of Fe2O3, 0.18% of TiO2, 0.12% of CaO, 0.25% of MgO, 3.16% of K2O, 0.37% of Na2O, and the rest is loss on ignition.

[0066] Further illustration, calculated by mass percentage, the chemical components of the bentonite include 68 - 70% of SiO2, 14.5 - 15% of Al2O3, 0.8 - 0.9% of Fe2O3, 0.1 - 0.2% of TiO2, 1.4 - 1.6% of CaO, 1.5 - 1.6% of MgO, 2.9 - 3% of K2O, and 1.6 - 1.7% of Na2O, and the rest is loss on ignition.

[0067] In this technical solution, preferably, magnesian soil with a CaO content of 0.7 - 0.8%, an MgO content of 19.5 - 20%, a K2O content of 0.2 - 0.3%, and a Na2O content of 0.2 - 0.3% calculated by mass percentage is added to the raw materials of the green body layer, which is beneficial to increasing the content of fluxes in the formulation system on the premise of avoiding softening and deformation of the green body layer during the firing process due to excessive fluxes in the formulation system, so as to achieve the purpose of reducing the firing temperature and shortening the firing cycle. At the same time, the SiO2 content in the bentonite is as high as 68 - 70%, and the Al2O3 content is 14.5 - 15%, which is beneficial to increasing the silicon content in the formulation and thus improving the overall strength of the rock slab. In addition, it should be noted that bentonite is classified according to the contents of Al2O3 and SiO2 and indeed belongs to the category of medium-aluminum and medium-silicon raw materials. However, the mineral composition of bentonite is mainly montmorillonite, which has a specific layered structure, making Al2O3 and SiO2 tightly combined in a specific chemical bond and arrangement, resulting in difficulty in separating and recombining Al2O3 and SiO2 in bentonite into mullite crystals during the sintering process. That is, although bentonite contains chemical components that can react to form mullite, due to the particularity of its mineral composition and structure, it is difficult to form mullite crystals.

[0068] Preferably, calculated by mass percentage, the chemical components of the bentonite include 68.45% of SiO2, 14.57% of Al2O3, 0.81% of Fe2O3, 0.11% of TiO2, 1.48% of CaO, 1.59% of MgO, 2.91% of K2O, 1.67% of Na2O, and the rest is loss on ignition.

[0069] Further explanation: Calculated by mass percentage, the chemical components of the yellow sand include 75-76% of SiO2, 10-11% of Al2O3, 0.5-1% of Fe2O3, 0.2-0.3% of TiO2, 0.3-0.4% of CaO, 0.2-0.3% of MgO, 1.8-2% of K2O, and 0.3-0.4% of Na2O, and the rest is loss on ignition.

[0070] In this technical solution, it is preferred to add yellow sand with a SiO2 content of 75-76% and an Al2O3 content of 10-11% calculated by mass percentage to the raw materials of the green body layer, which is beneficial to increasing the content of silicon and aluminum in the formula, and thus beneficial to improving the strength of the rock slab.

[0071] Preferably, calculated by mass percentage, the chemical components of the yellow sand include 75.70% of SiO2, 10.24% of Al2O3, 0.93% of Fe2O3, 0.22% of TiO2, 0.33% of CaO, 0.23% of MgO, 1.89% of K2O, 0.32% of Na2O, and the rest is loss on ignition.

[0072] A preparation method of a low-temperature and fast-firing anti-cutting and cracking rock slab for preparing the above-mentioned low-temperature and fast-firing anti-cutting and cracking rock slab, comprising the following steps:

[0073] A. Mix the formula amounts of bentonite, bauxite, magnesia soil, waste brick powder, washed mud, bluestone and yellow sand evenly, add water for ball milling and sieving to obtain a slurry; spray granulate the slurry to obtain a green body; press the green body into shape and dry it to obtain a green body layer; wherein, the fineness of the ball milling is 325 mesh sieve, and calculated by mass percentage, the screen residue is 1.3-1.8%.

[0074] B. Apply a base glaze on the surface of the green body layer to obtain a base glaze layer.

[0075] C. Print color ink on the surface of the base glaze layer according to a preset pattern to obtain a decorative layer.

[0076] D. Apply a polishing glaze on the surface of the decorative layer to obtain a polishing glaze layer.

[0077] E. Dry and then fire in a kiln to obtain an anti-cutting and cracking rock slab; wherein, the firing temperature of the anti-cutting and cracking rock slab ≤ 1223 °C, and the firing cycle is 35-38 min.

[0078] The present technical solution also proposes a preparation method for a low-temperature fast-firing anti-cutting and crack-resistant rock slab. The preparation method is simple and highly operable, which is conducive to ensuring the relevant properties of the rock slab during the preparation process. It should be noted that the base glaze layer in the present technical solution is applied by the conventional base glaze in the ceramic field, the decorative layer is printed by the conventional color ink in the ceramic field, and the polishing glaze layer is applied by the conventional polishing glaze in the ceramic field. No further description will be made on the base glaze, color ink, and polishing glaze here.

[0079] Specifically, when preparing the slurry in the present technical solution, the fineness of ball milling is limited to 325 mesh sieve, and the sieve residue is limited to 1.3 - 1.8%. By controlling the fineness of ball milling and the sieve residue, it is not only conducive to the smooth progress of the subsequent sieving operation, but also conducive to the more thorough chemical reaction of each raw material in the formula during the calcination process, the full decomposition of gaseous products, and the effective reduction of the generation of impurity phases and voids, thus being more conducive to forming a more uniform microstructure and further improving the anti-cutting and crack-resistant performance.

[0080] Further explanation, in step A, the specific method of sieving is as follows: The raw materials of the green body layer after ball milling with water are filtered successively through a 40-mesh sieve, a 60-mesh sieve, and an 80-mesh sieve once, and then filtered through a 90-mesh sieve twice.

[0081] The raw materials of the green body layer after ball milling with water contain particles of different particle sizes. Directly using a 90-mesh sieve for filtration is likely to cause sieve blockage and affect production efficiency. Therefore, the present technical solution adopts a hierarchical filtration strategy, specifically: using a 40-mesh sieve for filtration to remove coarse particles with a particle size greater than 0.364 mm; subsequently, using a 60-mesh sieve for further filtration to remove particles with a particle size greater than 0.245 mm; then, using an 80-mesh sieve for continuous filtration to remove particles with a particle size greater than 0.185 mm; finally, filtering through a 90-mesh sieve twice to ensure the removal of all particles with a particle size greater than 0.165 mm. The above series of filtration steps effectively reduce the content of coarse particles in the slurry, making the reaction of the green body layer more sufficient during the high-temperature firing process, avoiding the formation of defects or voids due to large particles, and thus reducing the generation of cracking points and enhancing the anti-cutting and crack-resistant performance.

[0082] In addition, the reason for choosing to filter through a 90-mesh sieve twice is as follows: On the one hand, the sieve may have imperceptible damage during use. Despite regular inspection measures, double filtration can further ensure that no particles are mixed in due to a damaged sieve; on the other hand, when the sieve mesh number exceeds 90 mesh, the filtration efficiency will decrease significantly, affecting the overall production capacity.

[0083] Further explanation, in step E, the firing curve of the anti-cutting and crack-resistant rock slab includes a preheating section, a front temperature section, a middle temperature section, a high temperature section, a transition section, a rapid cooling section, and a slow cooling section;

[0084] The top temperature of the preheating section rises from room temperature to 854°C, and the bottom temperature rises from room temperature to 841°C, which takes 5 to 5.4 minutes;

[0085] The top temperature of the front temperature section increased from 854°C to 1080°C, and the bottom temperature increased from 841°C to 1090°C, which took 5.1 to 5.7 minutes;

[0086] The top temperature of the medium temperature section rises from 1080°C to 1194°C, and the bottom temperature rises from 1090°C to 1205°C, which takes 5.5 to 5.8 minutes;

[0087] The top temperature of the high temperature section increased from 1194°C to 1204°C, and the bottom temperature increased from 1205°C to 1223°C, which took 4.5 to 5 minutes;

[0088] The top temperature of the transition section drops from 1204°C to 950°C, and the bottom temperature drops from 1223°C to 950°C, which takes 2 to 2.1 minutes;

[0089] The top temperature of the quenching section drops from 950°C to 584°C, and the bottom temperature drops from 950°C to 586°C, which takes 2 to 2.5 minutes;

[0090] The top temperature of the slow cooling section dropped from 584° C. to 97° C., and the bottom temperature dropped from 586° C. to 97° C., which took 11 to 11.6 minutes.

[0091] This technical solution optimizes the firing curve, which is beneficial to ensure the performance of the rock board. In addition, since the firing cycle is relatively fixed, if the time of the pre-temperature section is too long, it will cause the medium temperature, high temperature section and cooling section to be shortened in disguise, thus affecting the quality of the product. Therefore, the time of the pre-temperature section in this technical solution is limited to no more than 7 minutes, which is beneficial to ensure the performance of the product under the premise of fast firing.

[0092] Furthermore, the technical solution also optimizes the duration of the rapid cooling section and the slow cooling section. The rapid cooling section lasts for more than 2 minutes, while the slow cooling section lasts for more than 10 minutes, aiming to slow down the cooling rate, thereby reducing the phase change rate of free quartz in the green body layer, reducing microcracks caused by volume changes, and effectively improving the anti-cutting cracking performance.

[0093] Furthermore, due to the difference in shrinkage rates between the glaze layer (top layer) and the body layer (bottom layer) during the firing process, the rock slab is prone to concave or convex deformation. In addition, insufficient oxidation inside the body layer easily leads to black core oxidation, and the black core oxidation is usually related to the temperature distribution at the top and bottom in the preheating section of the firing curve. Therefore, by limiting the bottom temperature and top temperature at each stage of the firing curve in this application, it is not only beneficial to avoid deformation of the fired rock slab, thereby ensuring its flatness, but also beneficial to avoid black core oxidation inside the rock slab and ensure its quality.

[0094] It should be noted that the firing temperature of the rock slab refers to its highest calcination temperature. Therefore, the firing temperature of the rock slab in this technical solution is as low as 1223 °C. Compared with the traditional process, this firing temperature is relatively low, but it can still meet the product performance requirements.

[0095] The technical solution of the present invention will be further described below through specific embodiments.

[0096] Test method:

[0097] Anti-cutting and cracking performance: Take 4 fired rock slabs to obtain 4 rock slabs to be tested with a specification of 1500×750 mm (that is, a length of 1500 mm and a width of 750 mm). Cut the 4 rock slabs to be tested 7 times along the length direction, and the cutting spacing is 10 mm. If none of the 4 rock slabs to be tested break or chip during the cutting process, the anti-cutting and cracking performance is qualified.

[0098] Modulus of rupture: Test the modulus of rupture of the rock slab in accordance with "GB / T 3810.4-2016 Test methods for ceramic tiles - Part 4: Determination of modulus of rupture and breaking strength".

[0099] Breaking strength: Test the breaking strength of the rock slab in accordance with "GB / T 3810.4-2016 Test methods for ceramic tiles - Part 4: Determination of modulus of rupture and breaking strength".

[0100] In the examples and comparative examples of the present invention, calculated by mass percentage, the chemical composition of bluestone includes 70.65% SiO2, 14.30% Al2O3, 3.16% Fe2O3, 0.28% TiO2, 1.05% CaO, 1.29% MgO, 1.36% K2O, 3.92% Na2O, and the rest is loss on ignition;

[0101] Calculated by mass percentage, the chemical composition of bentonite includes 68.45% SiO2, 14.57% Al2O3, 0.81% Fe2O3, 0.11% TiO2, 1.48% CaO, 1.59% MgO, 2.91% K2O, 1.67% Na2O, and the rest is loss on ignition.

[0102] Calculated by mass percentage, the chemical composition of waste brick powder includes 65.67% of SiO2, 18.50% of Al2O3, 1.75% of Fe2O3, 0.50% of TiO2, 0.62% of CaO, 1.77% of MgO, 1.92% of K2O, 2.09% of Na2O, and the rest is loss on ignition.

[0103] Calculated by mass percentage, the chemical composition of magnesian soil includes 62.585% of SiO2, 5.79% of Al2O3, 1.615% of Fe2O3, 0.13% of TiO2, 0.79% of CaO, 19.5% of MgO, 0.25% of K2O, 0.245% of Na2O, and the rest is loss on ignition.

[0104] Calculated by mass percentage, the chemical composition of bauxite includes 36.45% of SiO2, 46.13% of Al2O3, 1.02% of Fe2O3, 1.33% of TiO2, 0.40% of CaO, 0.22% of MgO, 2.74% of K2O, 0.30% of Na2O.

[0105] Calculated by mass percentage, the chemical composition of washed mud includes 52.27% of SiO2, 32.5% of Al2O3, 1.41% of Fe2O3, 0.18% of TiO2, 0.12% of CaO, 0.25% of MgO, 3.16% of K2O, 0.37% of Na2O, and the rest is loss on ignition.

[0106] Calculated by mass percentage, the chemical composition of yellow sand includes 75.70% of SiO2, 10.24% of Al2O3, 0.93% of Fe2O3, 0.22% of TiO2, 0.33% of CaO, 0.23% of MgO, 1.89% of K2O, 0.32% of Na2O, and the rest is loss on ignition.

[0107] In addition, for those without specific technologies or conditions indicated in the examples and comparative examples, they are carried out according to the technologies or conditions described in the literature in this field or according to the product specifications. For the reagents or instruments without the manufacturer indicated, they are all conventional products that can be obtained through commercial purchase.

[0108] Example 1

[0109] A. Mix 3 parts of bentonite, 10 parts of bauxite, 4 parts of magnesia soil, 26 parts of waste brick powder with a particle size of 0.8 mm, 10 parts of washed mud, 24 parts of bluestone and 23 parts of yellow sand evenly, add water for ball milling and sieving to obtain a slurry; spray granulate the slurry to obtain a green body; press and form the green body, and dry it to obtain a green body layer; among them, the fineness of ball milling is 325 mesh sieve, and calculated by mass percentage, the screen residue is 1.3%; the specific method of sieving is: filter the raw materials of the green body layer after adding water for ball milling through a 40-mesh sieve, a 60-mesh sieve, and an 80-mesh sieve in sequence, and then filter through a 90-mesh sieve twice;

[0110] B. Apply a base glaze on the surface of the green body layer to obtain a base glaze layer;

[0111] C. Print color ink on the surface of the base glaze layer according to a preset pattern to obtain a decorative layer;

[0112] D. Apply a polished glaze on the surface of the decorative layer to obtain a polished glaze layer;

[0113] E. Dry and then fire in a kiln to obtain a cut-resistant rock slab; among them, the firing curve of the cut-resistant rock slab includes a preheating section, a pre-temperature section, a medium-temperature section, a high-temperature section, a transition section, a rapid cooling section and a slow cooling section; the top temperature of the preheating section rises from room temperature to 854 °C, and the bottom temperature rises from room temperature to 841 °C, taking 5.41 min; the top temperature of the pre-temperature section rises from 854 °C to 1080 °C, and the bottom temperature rises from 841 °C to 1090 °C, taking 5.41 min; the top temperature of the medium-temperature section rises from 1080 °C to 1194 °C, and the bottom temperature rises from 1090 °C to 1205 °C, taking 5.8 min; the top temperature of the high-temperature section rises from 1194 °C to 1204 °C, and the bottom temperature rises from 1205 °C to 1223 °C, taking 4.99 min; the top temperature of the transition section drops from 1204 °C to 950 °C, and the bottom temperature drops from 1223 °C to 950 °C, taking 2.08 min; the top temperature of the rapid cooling section drops from 950 °C to 584 °C, and the bottom temperature drops from 950 °C to 586 °C, taking 2.5 min; the top temperature of the slow cooling section drops from 584 °C to 97 °C, and the bottom temperature drops from 586 °C to 97 °C, taking 11.6 min.

[0114] Example 2

[0115] A. Mix 3 parts of bentonite, 12 parts of bauxite, 5 parts of magnesia soil, 28 parts of waste brick powder with a particle size of 0.7 mm, 10 parts of washed mud, 22 parts of bluestone and 21 parts of yellow sand evenly, add water for ball milling and sieving to obtain a slurry; spray granulate the slurry to obtain a green body; press the green body into shape and dry it to obtain a green body layer; among them, the fineness of ball milling is 325 mesh sieve, and calculated by mass percentage, the screen residue is 1.5%; the specific method of sieving is: filter the raw materials of the green body layer after adding water for ball milling through a 40-mesh screen, a 60-mesh screen, and an 80-mesh screen in sequence, and then filter through a 90-mesh screen twice;

[0116] B. Apply a base glaze on the surface of the green body layer to obtain a base glaze layer;

[0117] C. Print color ink on the surface of the base glaze layer according to a preset pattern to obtain a decorative layer;

[0118] D. Apply a polishing glaze on the surface of the decorative layer to obtain a polishing glaze layer;

[0119] E. Dry and then fire in a kiln to obtain a rock plate resistant to cutting and cracking; among them, the firing curve of the rock plate resistant to cutting and cracking includes a preheating section, a pre-temperature section, a pre-temperature section, a medium-temperature section, a high-temperature section, a transition section, a rapid cooling section and a slow cooling section; the top temperature of the preheating section rises from room temperature to 854 °C, and the bottom temperature rises from room temperature to 841 °C, taking 5.2 min; the top temperature of the pre-temperature section rises from 854 °C to 1080 °C, and the bottom temperature rises from 841 °C to 1090 °C, taking 5.2 min; the top temperature of the medium-temperature section rises from 1080 °C to 1194 °C, and the bottom temperature rises from 1090 °C to 1205 °C, taking 5.5 min; the top temperature of the high-temperature section rises from 1194 °C to 1204 °C, and the bottom temperature rises from 1205 °C to 1223 °C, taking 4.5 min; the top temperature of the transition section drops from 1204 °C to 950 °C, and the bottom temperature drops from 1223 °C to 950 °C, taking 2 min; the top temperature of the rapid cooling section drops from 950 °C to 584 °C, and the bottom temperature drops from 950 °C to 586 °C, taking 2.5 min; the top temperature of the slow cooling section drops from 584 °C to 97 °C, and the bottom temperature drops from 586 °C to 97 °C, taking 11.2 min.

[0120] Example 3

[0121] A. Mix 2 parts of bentonite, 8 parts of bauxite, 5 parts of magnesia soil, 28 parts of waste brick powder with a particle size of 0.6 mm, 10 parts of washed mud, 22 parts of bluestone and 23 parts of yellow sand evenly, add water for ball milling and sieving to obtain a slurry; spray granulate the slurry to obtain a green body; press the green body into shape and dry it to obtain a green body layer; among them, the fineness of ball milling is 325 mesh sieve, and calculated by mass percentage, the screen residue is 1.4%; the specific method of sieving is: filter the raw materials of the green body layer after adding water for ball milling through a 40-mesh sieve, a 60-mesh sieve and an 80-mesh sieve in sequence, and then filter through a 90-mesh sieve twice;

[0122] B. Apply a base glaze on the surface of the green body layer to obtain a base glaze layer;

[0123] C. Print color ink on the surface of the base glaze layer according to a preset pattern to obtain a decorative layer;

[0124] D. Apply a polished glaze on the surface of the decorative layer to obtain a polished glaze layer;

[0125] E. Dry and then fire in a kiln to obtain an anti-cutting rock slab; among them, the firing curve of the anti-cutting rock slab includes a preheating section, a first pre-temperature section, a strong oxidation section, a second pre-temperature section, a medium temperature section, a high temperature section, a transition section, a rapid cooling section and a slow cooling section; the top temperature of the preheating section rises from room temperature to 854 °C, and the bottom temperature rises from room temperature to 841 °C, taking 5.1 min; the top temperature of the pre-temperature section rises from 854 °C to 1080 °C, and the bottom temperature rises from 841 °C to 1090 °C, taking 5.2 min; the top temperature of the medium temperature section rises from 1080 °C to 1194 °C, and the bottom temperature rises from 1090 °C to 1205 °C, taking 5.6 min; the top temperature of the high temperature section rises from 1194 °C to 1204 °C, and the bottom temperature rises from 1205 °C to 1223 °C, taking 4.8 min; the top temperature of the transition section drops from 1204 °C to 950 °C, and the bottom temperature drops from 1223 °C to 950 °C, taking 2.1 min; the top temperature of the rapid cooling section drops from 950 °C to 584 °C, and the bottom temperature drops from 950 °C to 586 °C, taking 2.3 min; the top temperature of the slow cooling section drops from 584 °C to 97 °C, and the bottom temperature drops from 586 °C to 97 °C, taking 11.3 min.

[0126] Comparative Example 1

[0127] The preparation method and raw materials of Comparative Example 1 are the same as those of Example 1, except that the raw materials of the green body layer in Comparative Example 1 do not add waste brick powder.

[0128] Comparative Example 2

[0129] The preparation method and raw materials of Comparative Example 2 are the same as those of Example 1, except that the raw materials of the green body layer in Comparative Example 2 do not add bluestone.

[0130] The rock slabs were prepared by the preparation methods in the above-mentioned embodiment and comparative example respectively, and the obtained rock slabs were tested for their anti-cutting cracking performance. The results are shown in Table 1 below.

[0131] Table 1 Performance test results of different rock plates in the embodiments and comparative examples

[0132] Performance test items Whether chipping occurs at the edges Modulus of rupture (MPa) Breaking strength (N) Example 1 No chipping occurs at the edges 54.82 2518 Example 2 No chipping occurs at the edges 53.72 2479 Example 3 No chipping occurs at the edges 53.41 2430 Comparative example 1 Chipping occurs at the edges 44.71 1985 Comparative example 2 Chipping occurs at the edges 45.35 2072

[0133] From the performance test results of each embodiment in the above table, it can be seen that the rock slab prepared by the preparation method of this scheme can be fired under the firing conditions of a firing temperature as low as 1223°C and a firing cycle of 35 to 38 minutes, and there is no edge collapse, and the rupture modulus is ≥53MPa, the destructive strength is ≥2400N, and it has high strength and resistance to cutting cracks.

[0134] Since no waste brick powder was added in Comparative Example 1 and no bluestone was added in Comparative Example 2, the fluxing effect of the above raw materials could not be exerted, so that the slab could not be completely calcined, and the obtained slab contained sandwich raw materials, which affected the reduction of the anti-cutting cracking performance. At the same time, it also led to a reduction in the amount of mullite crystals uniformly dispersed in the glass phase, further leading to a reduction in the anti-cutting cracking performance and strength of the slab.

[0135] The technical principle of the present invention is described above in conjunction with specific embodiments. These descriptions are only for explaining the principle of the present invention and cannot be interpreted as limiting the scope of protection of the present invention in any way. Based on the explanations herein, those skilled in the art can associate other specific implementations of the present invention without paying creative labor, and these methods will fall within the scope of protection of the present invention.

Claims

1. A low-temperature fast-burning anti-cutting and cracking rock board, characterized in that: It includes a body layer, a base glaze layer, a decorative layer and a polishing glaze layer which are arranged in sequence from bottom to top; Calculated by weight, the raw materials of the green body layer include: 2-4 parts of bentonite, 8-12 parts of bauxite, 3-5 parts of magnesia clay, 22-28 parts of waste brick powder, 8-12 parts of washed mud, 22-26 parts of bluestone and 21-25 parts of yellow sand; Calculated by mass percentage, the chemical composition of the waste brick powder includes SiO2 65-66%, Al2O3 18-19%, Fe2O3 1.7-1.8%, TiO2 0.50-1%, CaO 0.5-0.7%, MgO 1.7-1.8%, K2O 1.9-2% and Na2O 2-2.1%, and the rest is loss on ignition; Calculated by mass percentage, the chemical composition of the bluestone includes SiO2 70-71%, Al2O3 14-14.5%, Fe2O3 3.0-3.2%, TiO2 0.2-0.3%, CaO 1-1.1%, MgO 1.2-1.4%, K2O 1.3-1.5% and Na2O 3.8-4.0%, and the rest is loss on ignition.

2. A low temperature fast burning anti-cutting cracking rock board according to claim 1, characterized in that: The particle size of the waste brick powder is ≤0.85 mm.

3. The low-temperature fast-burning anti-cutting and cracking rock board according to claim 1, characterized in that: Calculated by mass percentage, the chemical composition of the magnesia soil includes SiO2 62-63%, Al2O3 5.7-5.8%, Fe2O3 1.6-1.7%, TiO2 0.1-0.2%, CaO 0.7-0.8%, MgO 19.5-20%, K2O 0.2-0.3% and Na2O 0.2-0.3%, and the rest is loss on ignition.

4. The low-temperature fast-burning anti-cutting and cracking rock board according to claim 1, characterized in that: Calculated by mass percentage, the chemical composition of the bauxite includes SiO2 36-37%, Al2O3 46-47%, Fe2O3 1-1.2%, TiO2 1.3-1.5%, CaO 0.4-0.5%, MgO 0.2-0.3%, K2O 2.6-2.8% and Na2O 0.3-0.5%, and the rest is ignition loss.

5. The low-temperature fast-burning anti-cutting and cracking rock board according to claim 1, characterized in that: Calculated by mass percentage, the chemical composition of the washed mud includes SiO2 50-53%, Al2O3 31-33%, Fe2O3 1.4-1.5%, TiO2 0.1-0.2%, CaO 0.1-0.2%, MgO 0.2-0.3%, K2O 3-3.2% and Na2O 0.3-0.4%, and the rest is loss on ignition.

6. The low-temperature fast-burning anti-cutting and cracking rock board according to claim 1, characterized in that: Calculated by mass percentage, the chemical composition of the bentonite includes SiO2 68-70%, Al2O3 14.5-15%, Fe2O3 0.8-0.9%, TiO2 0.1-0.2%, CaO 1.4-1.6%, MgO 1.5-1.6%, K2O 2.9-3% and Na2O 1.6-1.7%, and the rest is loss on ignition.

7. The low-temperature fast-burning anti-cutting and cracking rock board according to claim 1, characterized in that: Calculated by mass percentage, the chemical composition of the yellow sand includes SiO2 75-76%, Al2O3 10-11%, Fe2O3 0.5-1%, TiO2 0.2-0.3%, CaO 0.3-0.4%, MgO 0.2-0.3%, K2O 1.8-2% and Na2O 0.3-0.4%, and the rest is loss on ignition.

8. A method for preparing a low-temperature fast-firing resistant cutting and cracking rock plate, characterized in that: The method for preparing the low-temperature fast-burning anti-cutting and cracking rock board as claimed in any one of claims 1 to 7 comprises the following steps: A. After mixing the formulated amount of bentonite, bauxite, magnesia clay, waste brick powder, washed mud, bluestone and yellow sand evenly, adding water to ball mill and sieving to obtain slurry; spray granulating the slurry to obtain a blank; pressing the blank into shape, and drying to obtain a blank layer; wherein the fineness of the ball mill is 325 mesh sieve, and the sieve residue is 1.3-1.8% by mass percentage; B. Applying base glaze on the surface of the body layer to obtain a base glaze layer; C. Printing color ink on the surface of the base glaze layer according to a preset pattern to obtain a decorative layer; D. Apply glaze on the surface of the decorative layer to obtain a glaze layer; E. After drying, the slab is put into a kiln for firing to obtain a cutting-resistant rock board; wherein the firing temperature of the cutting-resistant rock board is ≤1223°C, and the firing cycle is 35 to 38 minutes.

9. The method for preparing a low-temperature fast-firing resistant cutting and cracking rock board according to claim 8, characterized in that: In step A, the specific method of screening is: filtering the raw material of the green body layer after water ball milling through a 40-mesh sieve, a 60-mesh sieve, and an 80-mesh sieve in sequence, and then filtering twice through a 90-mesh sieve.

10. The method for preparing a low-temperature fast-firing resistant cutting and cracking rock board according to claim 8, characterized in that: In step E, the firing curve of the anti-cutting and cracking rock plate includes a preheating section, a pre-temperature section, a medium temperature section, a high temperature section, a transition section, a rapid cooling section and a slow cooling section; The top temperature of the preheating section rises from room temperature to 854°C, and the bottom temperature rises from room temperature to 841°C, which takes 5 to 5.4 minutes; The top temperature of the front temperature section increased from 854°C to 1080°C, and the bottom temperature increased from 841°C to 1090°C, which took 5.1 to 5.7 minutes; The top temperature of the medium temperature section rises from 1080°C to 1194°C, and the bottom temperature rises from 1090°C to 1205°C, which takes 5.5 to 5.8 minutes; The top temperature of the high temperature section increased from 1194°C to 1204°C, and the bottom temperature increased from 1205°C to 1223°C, which took 4.5 to 5 minutes; The top temperature of the transition section drops from 1204°C to 950°C, and the bottom temperature drops from 1223°C to 950°C, which takes 2 to 2.1 minutes; The top temperature of the quenching section drops from 950°C to 584°C, and the bottom temperature drops from 950°C to 586°C, which takes 2 to 2.5 minutes; The top temperature of the slow cooling section dropped from 584° C. to 97° C., and the bottom temperature dropped from 586° C. to 97° C., which took 11 to 11.6 minutes.