Hole simulation generating agent and preparation method thereof as well as ceramic plate and preparation method thereof

Abstract

The invention provides a hole simulation generating agent and a preparation method thereof, a ceramic plate and a preparation method thereof, the hole simulation generating agent is used for being added into a backing material layer of the ceramic plate, and the hole simulation generating agent is prepared from the following raw materials in parts by weight: 0-15 parts of urea and / or liquid paraffin, 10-30 parts of production powder and 55-75 parts of special solid low-carbon fuel particles. According to the pore simulation generating agent prepared from the urea and / or the liquid paraffin, the production powder and the special solid low-carbon fuel particles, the urea and the liquid paraffin are relatively low in residual carbon content and are easy to decompose or burn mostly before 600 DEG C in a drying or sintering stage, so that the problems that an existing pore-foaming agent is too high in residual carbon content and cannot be easily decomposed or burnt at the temperature of 600 DEG C can be solved. And after high-temperature firing, the glaze cannot be completely volatilized as soon as possible, and a large number of glaze defects are easily caused.

Description

Technical Field

[0001] The present invention relates to the technical field of ceramic production, and particularly relates to a pore simulation generator, a preparation method thereof, a ceramic plate and a preparation method thereof. Background Art

[0002] The firmness of tile laying is related to people's livelihood safety. Due to large climate temperature differences or long-term exposure to wind, sun, rain, and the inconsistent deformation rates of tiles and bonding materials, tile panels are prone to detachment, resulting in the shedding of tile surfaces, which may very likely lead to safety accidents. By changing the structure of the tile back pattern, the bonding strength between the tile and the bonded wall can be increased.

[0003] Most of the current tile back patterns are formed by mold pressing. The depth of the ribs of the pressed back pattern is generally between 0.6 - 0.8 mm, but the back pattern obtained by mold pressing is very limited. Other back pattern preparation methods include applying glue and adding pore-forming agents. However, the back patterns obtained by mold forming and applying glue will cause the ceramic tiles to be easily detached during later laying and bonding; the existing pore-forming agents are selected from polystyrene, modified starch, polymethyl methacrylate, polyethylene, polycarbonate, polybutene, polyisoprene. Such pore-forming agents have too high a residual carbon content and cannot be completely volatilized as soon as possible after high-temperature firing, easily causing a large number of glaze defects.

[0004] Therefore, there are defects in the prior art and it needs to be improved and developed. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a pore simulation generator, a preparation method thereof, a ceramic plate and a preparation method thereof, aiming at solving the problem in the prior art that the residual carbon content of the pore-forming agent is too high and it cannot be completely volatilized as soon as possible after high-temperature firing, easily causing a large number of glaze defects.

[0006] The technical solution adopted by the present invention to solve the technical problem is as follows:

[0007] A pore simulation generator is used to be added to the base material layer of a ceramic plate. Among them, the raw material formula of the pore simulation generator is calculated by weight and includes:

[0008] Urea and / or liquid paraffin 0 - 15 parts, production powder 10 - 30 parts, special solid low-carbon fuel particles 55 - 75 parts.

[0009] In an embodiment of the present application, the raw material formula of the special solid low-carbon fuel particles is calculated by weight and includes:

[0010] 90 - 95 parts of industrial alcohol, 30 - 40 parts of EPE powder, 4.6 - 6.6 parts of stearic acid, 1.0 - 1.2 parts of sodium hydroxide, 4 - 4.5 parts of water.

[0011] In an embodiment of the present application, the preparation steps of the special solid low - carbon fuel particles include:

[0012] Add stearic acid to industrial alcohol, heat and stir in a water bath, and obtain the first mixed solution after stirring evenly.

[0013] Add EPE powder to the first mixed solution, heat and stir in a water bath, and obtain the second mixed solution after stirring evenly.

[0014] Dissolve sodium hydroxide in water, and obtain the third mixed solution after shaking evenly.

[0015] Add industrial alcohol to the third mixed solution, heat and stir in a water bath, and obtain the fourth mixed solution after stirring evenly.

[0016] [[ID=I8]]Add the fourth mixed solution to the second mixed solution, heat and stir in a water bath, and naturally cool and solidify after stirring evenly to obtain a solidified body.

[0017] Cut the solidified body into special solid low - carbon fuel particles.

[0018] In an embodiment of the present application, the chemical composition of the production powder, by mass percentage, includes:

[0019] Loss on ignition 4 - 6%, SiO2 64 - 70%, Al2O3 20 - 22%, Fe2O3 0.1 - 0.3%, CaO 1 - 3%, MgO 1 - 3%, K2O 1 - 3%, Na2O 1 - 5%, Li2O 0 - 0.5% 。

[0020] In an embodiment of the present application, the pore - simulation generator exists in a solid form when the temperature is lower than 60°C, has a melting point or ignition point of 120 - 130°C, and has a high - temperature residual carbon content of less than 0.55% at 600°C.

[0021] The present application also provides a preparation method of the pore - simulation generator as described above, wherein the method includes:

[0022] Weigh 0 - 15 parts of urea and / or liquid paraffin, 10 - 30 parts of production powder, and 55 - 75 parts of special solid low - carbon fuel particles by weight, and mix them to form a powder mass.

[0023] Use a pair - roll rolling machine to press the powder mass into a thin cake.

[0024] After crushing the thin material cake, it is sieved through a 30-50 mesh sieve into solid powder mass particles, and the solid powder mass particles are used as the pore simulation generating agent.

[0025] This application also provides a method for preparing a ceramic plate. Among them, the method for preparing the ceramic plate includes:

[0026] Obtain the pre-prepared base material, mix the base material with the pore simulation generating agent as described above to obtain the base pattern powder;

[0027] According to the requirements of the preset digital fabric printing process, add the base pattern powder into the corresponding material tank of the all-through digital fabric printer, and first perform reverse digital fabric printing on the steel belt of the all-through digital fabric printer to form a base material layer;

[0028] Obtain the pre-prepared surface material, lay the surface material on the base material layer to form a surface material layer, and obtain a ceramic green body after drying; the ceramic green body is processed and then fired;

[0029] Among them, during the drying process, the pore simulation generating agent burns and volatilizes or decomposes into gas to form pores in the base material layer; during the firing process, the residual carbon after the pore simulation generating agent burns completely burns, and finally a ceramic plate with a pore back pattern structure feature is obtained.

[0030] In an embodiment of this application, laying a surface material layer on the base material layer and obtaining a ceramic green body after drying includes:

[0031] Lay a surface material layer on the base material layer, and dry it under the conditions of a drying temperature of 150-330 °C and a drying time of 65-95 min to obtain a ceramic green body.

[0032] In an embodiment of this application, the firing temperature of the ceramic green body is 1150-1220 °C, and the firing time is 45-85 minutes.

[0033] This application also provides a ceramic plate, where the ceramic plate is prepared by the method for preparing a ceramic plate as described above.

[0034] A pore simulation generator provided by the present application, its preparation method, a ceramic plate and its preparation method. The pore simulation generator is used to be added to the base material layer of the ceramic plate. The raw material formula of the pore simulation generator is calculated by weight and includes: 0-15 parts of urea and / or liquid paraffin, 10-30 parts of production powder, and 55-75 parts of special solid low-carbon fuel particles. By using the pore simulation generator prepared from urea and / or liquid paraffin, production powder and special solid low-carbon fuel particles, the residual carbon content of urea and liquid paraffin is relatively low and it is easy to be completely decomposed or burned. Therefore, it can solve the problem that the residual carbon content of the existing pore-forming agent is too high and it cannot be completely volatilized as soon as possible after high-temperature firing, which is likely to cause a large number of glaze defects. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 It is a schematic structural diagram of a ceramic plate in the present invention.

[0036] Figure 2 It is an effect diagram of pores in the first specific embodiment of the present invention.

[0037] Figure 3 It is an effect diagram of pores in the second specific embodiment of the present invention.

[0038] Figure 4 It is an effect diagram of pores in the third specific embodiment of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0039] In order to make the objectives, technical solutions and advantages of the present invention clearer and more definite, the following further describes the present invention in detail with reference to the accompanying drawings and by way of examples. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0040] In recent years, the production and demand of domestic ceramic slabs / large slabs have both shown a steady growth trend and continued to expand their applications. The development of ceramic machinery and equipment has gradually tended towards large slab and flexible production. Currently, there are mainly three forming methods for slabs / large slabs: dry pressing traditional forming, belt forming without a mold, and roll forming. Specifically, in the dry pressing traditional forming method, powder materials are loaded into a metal mold and compressed under the action of force. Part of the gas in the voids of the green body is discharged, the particles are displaced, gradually approach each other, and tightly bite each other, finally forming a green body with the same cross-section as the mold cross-section and the shapes of the upper and lower surfaces determined by the upper and lower punches of the mold. In the belt forming without a mold method, the powder materials are evenly distributed on the surface of the conveyor belt according to a predetermined size. After the cloth laying is completed, the conveyor belt transports it to the pressure device for pressing and forming. The cloth laying system of the roll forming method arranges ceramic powder materials on two very hard motor-driven traction steel belts. The rotation of the steel belt sends the ceramic powder materials with a consistent thickness into a pair of opposing pressing rolls for roll forming. It can produce brick blanks with a width of 1600 mm and an unlimited length. Roll forming has the characteristics of low power consumption, low noise, low pollution, high efficiency, and highly flexible production, and has incomparable advantages over traditional presses in terms of manufacturing, transportation, installation, etc.

[0041] For slabs in the cases of extra-large specifications and more thicknesses, the belt forming without a mold method and the roll forming method are generally common and have an absolute quality advantage. However, since tile adhesives are generally used for construction and paving abroad, most of the slab / large slab products produced by this equipment process are flat without back pattern designs. If the imported belts or steel belts with back patterns are frequently replaced, the cost will be relatively high. Using traditional roll forming, compared with the belt technology without a mold, the cost of the steel belt for three-dimensional engraving of back patterns is relatively high.

[0042] Currently, the main technical paths for the process ideas and methods of preparing back patterns are as follows: sticking glue on the steel belt, carving on the green body, and forming back patterns after the pore-forming agent is fired.

[0043] However, the existing pore-forming agents are selected from at least one of polystyrene, modified starch, polymethyl methacrylate, polyethylene, polycarbonate, polybutene, and polyisoprene, and have the following defects:

[0044] First, the carbon residue content of this type of pore-forming agent is too high, and it cannot be volatilized completely as soon as possible after high-temperature firing, which is likely to cause a large number of glaze defects and can only be limited to personalized travertine-like products.

[0045] Second, in the above-mentioned pore-forming agent process, the pore-forming agent itself has no bonding property, its bulk density is very low, and it is not easy to combine with the powder materials, resulting in easy drifting, delamination, and chromatography in the digital cloth distributor, and thus the positioning fails to achieve the expected design pattern position effect.

[0046] The embodiments of the present application are to solve the problems of positioning failure in the fabric feeding stage and glaze defects in the production process that often occur in the conventional high-temperature firing pore-forming technology for forming the back pattern, and to further improve the positioning problems of the pore-forming agent materials that often occur in the digital fabricator, such as easy drifting, stratification, and chromatography, in the drying or preheating low- and medium-temperature zones of the kiln. A pore simulation generator is provided, which does not require the addition of a mold for forming the back pattern, has stronger production applicability, greatly improves the product quality, and saves the production cost.

[0047] As Figure 1 shown, the embodiments of the present application provide a pore simulation generator for adding to the base material layer of a ceramic plate. The raw material formula of the pore simulation generator is calculated by weight and includes:

[0048] 0-15 parts of urea and / or liquid paraffin, 10-30 parts of production powder, and 55-75 parts of special solid low-carbon fuel particles.

[0049] Specifically, the base material layer of the ceramic plate in the present application includes: the base material and the pore simulation generator. In one embodiment, the mass ratio of the base material to the pore simulation generator is (95-98):(2-5). Different addition amounts of the pore simulation generator can form back patterns with different pore structures. As the dosage of the pore-forming agent increases continuously, the formed pore structure changes from isolated pores and connected pores to groove structures. The addition amount of the pore-forming agent can be adjusted according to the actual paving effect requirements in the later stage.

[0050] The embodiments of the present application utilize the pore simulation generator to form irregular isolated pores, connected pores or groove structures after drying and firing, and use digital fabric printing as the back pattern of ceramic rock plates or ceramic large plates, which can replace the traditional die-pressed back pattern process. Specifically, compared with the back pattern structure formed by die molding, the present invention combines the fabric printing with the special pore simulation production technology, making the pattern of the back pattern more flexible and diverse. Moreover, the cross-section or projection of the pore structure formed by the pore simulation generator is irregular. Compared with the flat surface formed by die molding, it can increase the contact area of adhesives such as traditional concrete mortar or tile adhesive during later paving and bonding, thereby improving the bonding strength of the ceramic plate.

[0051] In the embodiments of the present application, the raw material formula of the special solid low-carbon fuel particles is calculated by weight and includes:

[0052] 90-95 parts of industrial alcohol, 30-40 parts of EPE powder, 4.6-6.6 parts of stearic acid, 1.0-1.2 parts of sodium hydroxide, and 4-4.5 parts of water.

[0053] Specifically, expanded polyethylen (EPE) is made by physically foaming low-density polyethylene, and its melting point ranges from 110°C to 125°C. EPE powder is the physical form of EPE. In an environment below 60°C, the EPE powder maintains a solid particle form. Stearic acid is a common fatty acid, and its melting point ranges from 56°C to 69.6°C. Therefore, in an environment below 60°C, stearic acid will gradually solidify into a solid state. Sodium hydroxide (NaOH) is a strong base, and its melting point is 318°C. In an environment below 60°C, sodium hydroxide remains solid. Therefore, most of the raw materials of the special solid low-carbon fuel particles exist in a solid form at a temperature below 60°C, and the single material size particle diameter is controlled to be less than 60 mesh. After exceeding 150°C, most of them can volatilize or burn, and the residual carbon part can also be completely burned with a very low residual carbon content at about 600°C in the later firing process, so it will not cause other defects on the glaze surface. Gas will be generated and holes will be left during the drying or firing stage of the ceramic rock slab or large slab, and the high-temperature residual carbon content at about 600°C is less than 0.55%.

[0054] One or more mixtures such as urea or biomass fuel, although their residual carbon content is low and they are easy to completely decompose or burn, and will not cause other defects on the glaze surface, but if the solid particle material itself has no bonding property, its bulk density is low, it is not easy to combine with the powder material, and it is extremely easy to disperse into powder during the processing process and is not easy to form solid powder agglomerate particles. Similarly, it will also cause easy drifting, delamination, and chromatography in the digital cloth feeder, and the holes formed cannot reach the expected design pattern effect due to the inability to fix the position.

[0055] In the special solid low-carbon fuel particles of the present application, stearic acid and sodium hydroxide undergo a saponification reaction under the condition of water bath heating to generate sodium stearate and water. Sodium stearate is a long-chain fatty acid salt and has surfactant characteristics. Sodium stearate acts as a binder in the system, and its long-chain structure can form physical or chemical bonds with raw materials such as industrial alcohol and EPE powder. Specifically, the long-chain molecules of sodium stearate are intertwined with the microporous structure of the EPE powder through van der Waals forces to form mechanical occlusion; the polar end (carboxylate group) of sodium stearate forms a hydrogen bond with the hydroxyl group in industrial alcohol, and the non-polar end (long-chain alkyl group) interacts with the hydrophobic part of the EPE powder to enhance the cohesion within the system. Industrial alcohol acts as a solvent to promote the uniform dispersion of stearic acid and sodium hydroxide and accelerate the progress of the saponification reaction; the sodium stearate generated by the reaction has a low solubility in alcohol and forms a gel system after cooling, binding the alcohol molecules between the interconnected macromolecules, making the system in a non-flowing state, thereby solidifying and forming. The EPE powder is a polyethylene foaming material with a porous structure, which can adsorb sodium stearate and alcohol to form a stable network structure.

[0056] Therefore, the special solid low-carbon fuel particles of the present application have bonding properties, are easy to combine with production powders, promote the formation of solid powder mass particles by the pore simulation generator, and thus are not prone to drift, stratification, and chromatography in the digital cloth feeder, improving the success rate of pore formation.

[0057] In an embodiment of the present application, the preparation steps of the special solid low-carbon fuel particles include:

[0058] Step S10: Add stearic acid to industrial alcohol, heat and stir in a water bath, and obtain a first mixed solution after stirring evenly.

[0059] Step S20: Add EPE powder to the first mixed solution, heat and stir in a water bath, and obtain a second mixed solution after stirring evenly.

[0060] Step S30: Dissolve sodium hydroxide in water, shake evenly to obtain a third mixed solution.

[0061] Step S40: Add industrial alcohol to the third mixed solution, heat and stir in a water bath, and obtain a fourth mixed solution after stirring evenly.

[0062] Step S50: Add the fourth mixed solution to the second mixed solution, heat and stir in a water bath, and let it cool and solidify naturally after stirring evenly to obtain a solidified body.

[0063] Step S60: Cut the solidified body into special solid low-carbon fuel particles.

[0064] Specifically, in step S10, add stearic acid to industrial alcohol, heat and stir in a water bath, and keep the water bath temperature at 60°C during stirring. Stir for 3 - 4 minutes until evenly mixed to obtain a first mixed solution. In step S20, add EPE powder passing through 60 meshes to the first mixed solution, heat and stir in a water bath, and keep the water bath temperature at 60°C during stirring. Stir for 5 - 6 minutes until evenly mixed to obtain a second mixed solution. In step S30, dissolve 90 - 95 parts of sodium hydroxide in 4 - 4.5 parts of water, shake for 2 - 3 minutes until evenly mixed to obtain a third mixed solution. In step S40, add industrial alcohol to the third mixed solution, heat and stir in a water bath, and keep the water bath temperature at 60°C during stirring. Stir for 2 - 3 minutes until evenly mixed to obtain a fourth mixed solution. In step S50, add the fourth mixed solution to the second mixed solution, heat and stir in a water bath, and keep the water bath temperature at 60°C during stirring. Stir for 4 - 5 minutes until evenly mixed, then let it cool and solidify naturally, and cut it into special solid low-carbon fuel particles with a blade.

[0065] In the embodiments of the present application, through step-by-step mixing, it is ensured that all raw materials react fully and are evenly dispersed. First, stearic acid is mixed with industrial alcohol, then pearl cotton powder is added, and finally it is mixed with sodium hydroxide solution, avoiding uneven local reactions that may be caused by direct mixing; water bath heating provides a mild and uniform heating environment, which is conducive to the saponification reaction and at the same time prevents the decomposition of raw materials due to local overheating.

[0066] In the embodiments of the present application, the chemical composition of the production powder, by mass percentage, includes:

[0067] Loss on ignition 4 - 6%, SiO2 64 - 70%, Al2O3 20 - 22%, Fe2O3 0.1 - 0.3%, CaO 1 - 3%, MgO 1 - 3%, K2O 1 - 3%, Na2O 1 - 5%, Li2O 0 - 0.5% 。

[0068] Specifically, the moisture content of the production powder is 8 - 10%.

[0069] In an embodiment of the present application, the pore simulation generator exists in a solid form when the temperature is below 60°C, has a melting point or ignition point of 120 - 130°C, and the high-temperature residual carbon content at 600°C is less than 0.55%. The high-temperature residual carbon content refers to the mass percentage of the charred black residue formed after the organic matter evaporates, cracks, and burns under specific high-temperature conditions, which reflects the carbonaceous components remaining after the decomposition of the substance at high temperature.

[0070] The pore simulation generator of the present application has an extremely low residual carbon content, so it will not cause other defects on the glaze surface. The pore simulation generator has mostly volatilized or partially burned and decomposed during the high-temperature drying process of the ceramic rock slab and the ceramic large slab, and finally leaves pores.

[0071] The present application also provides a preparation method of the pore simulation generator as described above, and the method includes:

[0072] Step A10: Weigh 0 - 15 parts of urea and / or liquid paraffin, 10 - 30 parts of production powder, and 55 - 75 parts of special solid low-carbon fuel particles by weight, and mix them to form a powder mass;

[0073] Step A20: Use a pair-roll rolling mill to press the powder mass into a thin cake;

[0074] Step A30: After crushing the thin cake, sieve it through a 30 - 50 mesh sieve to form solid powder mass particles, and use the solid powder mass particles as the pore simulation generator.

[0075] Specifically, in step A10, after weighing and mixing the raw materials in the formula, it is appropriate that the mixture can be kneaded into a ball by hand without loosening, and the overall moisture content is controlled at 1%-3%. In step A20, it is conveyed to a small pair-roll rolling mill by a conveyor belt to form a thin cake. In step A30, after being crushed by a crusher or manually, it is sieved through a 30-50 mesh sieve to form solid powder mass particles of irregular shape for standby. The technical characteristic indexes of the solid powder mass particles are: the size particle diameter is 6-50 mesh.

[0076] The pore simulation generator of the embodiment of the present application is solid powder mass particles of irregular shape, added with special solid low-carbon fuel particles, and is made through processes such as mixing with part of the production powder, pair-roll rolling, granulation and crushing. It has an extremely low residual carbon content, will not cause other defects on the glaze surface, and is solid powder mass particles. Therefore, it is not easy to drift, layer, or chromatograph in the digital fabricator, improving the success rate of pore formation.

[0077] The present application also provides a method for preparing a ceramic plate, wherein the method for preparing the ceramic plate includes:

[0078] Step B10, obtaining a pre-prepared base material, mixing the base material with the pore simulation generator as described above to obtain base pattern powder;

[0079] Step B20, according to the requirements of the preset digital fabricating process, adding the base pattern powder into the corresponding material tank of the all-through digital fabricator, and first performing reverse digital fabricating on the steel belt of the all-through digital fabricator to form a base material layer;

[0080] Step B30, obtaining a pre-prepared surface material, laying the surface material on the base material layer to form a surface material layer, and obtaining a ceramic green body after drying; the ceramic green body is processed and then fired.

[0081] Wherein, during the drying process, the pore simulation generator burns and volatilizes or decomposes into gas to form pores in the base material layer; during the firing process, the residual carbon after the pore simulation generator burns completely burns, and finally a ceramic plate with a pore back pattern structure feature is obtained.

[0082] Specifically, in step B10, after wet grinding according to the preset formula process, spray granulation is performed to obtain the base material. The base material is mixed with the pore simulation generator in different proportions to obtain the base pattern powder for the all-through digital fabricator. In step B20, it is added into the corresponding material tank of the all-through digital fabricator according to the requirements of the digital fabricating process, and first reverse digital fabricating is performed on the steel belt to form a base material layer 100, as Figure 1As shown. In step B30, a fabric layer is laid on the base layer 100 to form a fabric layer 200; in step B40, the ceramic green body is processed according to the requirements of the conventional production process. During the drying and firing processes, the pore simulation generator volatilizes or decomposes into gas to form pores 110 in the base layer 100.

[0083] In one embodiment, the raw material formula compositions of the fabric layer and the base layer are the same to eliminate the material property differences caused by different raw material compositions and prevent delamination and deformation of the brick body.

[0084] The embodiment of the present application adopts a v-nature all-through digital fabric system, and the base layer and the fabric layer are laid successively. Among them, the base layer adopts a multi-tube digital powder fabric mechanism with a group of pre-designed patterns that can be thinly laid. A layer of production powder with a specific thickness and mixed with a pore simulation generator can be laid on the surface of the pressing steel belt. The mass of the pore simulation generator accounts for 0.5-3% of the total mass of the base material.

[0085] Specifically, when a ceramic rock slab or a ceramic large slab is press-molded, a roller pressing molding method is adopted. When fabricating, a base layer is first digitally laid by an all-through digital fabric system, then a fabric layer is laid, and then a ceramic slab is obtained through the conventional ceramic rock slab or ceramic large slab process flow.

[0086] The ceramic slab of the present invention is laid with the base layer according to the texture preset by the all-through digital fabric machine in a digital fabricating manner. Since a pore simulation generator is added to some powders, after high-temperature drying, the pore simulation generator naturally forms irregular isolated pores, through holes or groove structures through physical and chemical change effects, and is used as the back pattern of the ceramic rock slab or ceramic large slab after firing and stabilization. With the help of multi-tube digital fabric, flexible and diverse patterns can be achieved, breaking away from the limitations of traditional die pressing for back patterns. Moreover, the cross-section or projection of the hole stone structure formed by the pore simulation generator is irregular. Compared with the technical route of obtaining a flat back pattern by die molding or pasting glue and other methods, the probability of the ceramic rock slab / large slab falling off after paving is greatly reduced during the later paving and bonding process, solving the problem that traditional concrete mortar or tile adhesive is easy to fall off during the later paving construction process.

[0087] In one embodiment, the height ratio of the fabric layer to the base layer is (8-9):(1-2). Compared with the concave-convex die molding of the ceramic brick back pattern, since the surface is flat during pressing in the present invention, the requirement for the height ratio of the fabric layer to the base layer is lower, and the flexural strength of the brick body will not be reduced due to the density difference at the concave-convex parts.

[0088] In the embodiment of the present application, a fabric layer is laid on the base layer, and a ceramic green body is obtained after drying, including:

[0089] A surface material layer is arranged on the base material layer, and drying is performed under the conditions of a drying temperature of 150-330° C. and a drying time of 65-95 minutes to obtain a ceramic green body.

[0090] Specifically, in the temperature range of 150-330°C, the moisture in the green body gradually evaporates, the pores between the particles are reduced, and the structure becomes denser. The drying time of 65-95 minutes allows the moisture to be fully and evenly discharged, avoiding insufficient or excessive drying.

[0091] The present invention reduces defects such as cracks and bubbles in the green body under the conditions of a drying temperature of 150-330° C. and a drying time of 65-95 min, thereby improving product quality.

[0092] In one embodiment of the present application, the firing temperature of the ceramic body is 1150-1220° C., and the firing time is 45-85 minutes.

[0093] In the embodiment of the present application, at a temperature of 1150-1220°C, sufficient solid-phase reaction and liquid-phase sintering occur between the ceramic particles, the particles are more tightly bonded, the crystal structure in the ceramic is more stable, and it is not easy to react with chemical substances such as acids and alkalis, thereby improving the ability to resist chemical corrosion; the firing time of 45-85 minutes not only ensures the firing effect, but also improves production efficiency and reduces production costs.

[0094] This application has achieved the following results:

[0095] First, use a very cost-effective solution to improve the problem of ceramic rock slabs and large slabs easily falling off during the wall paving process, improve the beauty of the building and the safety of the later stage, increase the possibility of using traditional concrete mortar to pave rock slabs and large slabs, and reduce the cost of later paving.

[0096] Second, the pore simulation generating agent has a residual carbon content of less than 0.55% at a high temperature of about 600°C, exists in solid form below 60°C, has a melting point or ignition point of 120-130°C, and most of it can be volatilized or burned and decomposed after exceeding 150°C. The residual carbon part can also be completely burned at about 600°C during the later firing process. It has an extremely low residual carbon content and will not cause other defects in the glaze. The pore simulation generating agent has been mostly volatilized or burned and decomposed during the high-temperature drying process of the green body of ceramic rock slabs and ceramic large slabs, that is, the pores have basically been formed during the drying process of the green body; the pore effect is as follows Figure 2 、 Figure 3 and Figure 4 shown.

[0097] Third, the digital fabric mechanism is a preset equipment station for the roll-forming equipment itself, and no additional equipment investment is required.

[0098] Fourthly, the present invention adopts a processing method combining fabric and pore formation. After mixing the pore simulation generating agent powder and the base material, the bottom layer is directly laid. The pore simulation generating agent undergoes high-temperature drying and spontaneous combustion, and through physical and chemical changes, irregular isolated pores, through-holes or groove structures are formed as the back patterns of ceramic rock slabs and ceramic large slabs, improving the structure of the bottom of the slabs and large slabs, enabling them to be fully combined with concrete cement mortar during the paving process, and forming barbs, making it not easy to fall off. It can replace the traditional die-pressed back pattern process, with low cost and easy to promote.

[0099] The present application also provides a ceramic plate, which is prepared by the ceramic plate preparation method as described above.

[0100] The present invention provides a pore simulation generating agent and its preparation method, a ceramic plate and its preparation method. The pore simulation generating agent is used to be added to the base material layer of the ceramic plate. The raw material formula of the pore simulation generating agent is calculated by weight and includes: 0-15 parts of urea and / or liquid paraffin, 10-30 parts of production powder, and 55-75 parts of special solid low-carbon fuel particles. By using the pore simulation generating agent prepared from urea and / or liquid paraffin, production powder and special solid low-carbon fuel particles, the present application has a low residual carbon content for urea and liquid paraffin, which is easy to completely burn and decompose. Therefore, it can solve the problem that the existing pore-forming agent has too high a residual carbon content and cannot be completely volatilized as soon as possible after high-temperature firing, easily causing a large number of glaze defects.

[0101] It should be understood that the application of the present invention is not limited to the above examples. For those of ordinary skill in the art, improvements or transformations can be made according to the above description, and all such improvements and transformations should fall within the protection scope of the appended claims of the present invention.

Claims

1. A pore simulation generating agent for adding to the base layer of a ceramic plate, characterized in that The raw material formula of the pore simulation generating agent comprises, by weight: 0-15 parts of urea and / or liquid paraffin, 10-30 parts of production powder, and 55-75 parts of special solid low-carbon fuel particles.

2. The pore simulation generating agent according to claim 1, characterized in that, The raw material formula of the special solid low-carbon fuel particles includes, by weight: 90-95 parts of industrial alcohol, 30-40 parts of pearl cotton powder, 4.6-6.6 parts of stearic acid, 1.0-1.2 parts of sodium hydroxide, and 4-4.5 parts of water.

3. The pore simulation generating agent according to claim 1, characterized in that, The steps of preparing the specially prepared solid low-carbon fuel particles include: Add stearic acid to industrial alcohol, heat in a water bath and stir, and stir evenly to obtain a first mixed solution; Adding pearl cotton powder to the first mixed solution, heating in a water bath and stirring, and stirring evenly to obtain a second mixed solution; Add sodium hydroxide to water and dissolve it, then shake it evenly to obtain a third mixed solution; Adding industrial alcohol to the third mixed solution, heating in a water bath and stirring, and stirring until uniform, obtaining a fourth mixed solution; adding the fourth mixed liquid to the second mixed liquid, heating and stirring in a water bath, stirring evenly and then naturally cooling and solidifying to obtain a solidified body; The solidified body is cut into tailor-made solid low-carbon fuel particles.

4. The pore simulation generating agent according to claim 1, wherein The chemical composition of the production powder is calculated by mass percentage and includes: Loss on ignition 4 - 6%, SiO2 64 - 70%, Al2O3 20 - 22%, Fe2O3 0.1 - 0.3%, CaO 1 - 3%, MgO 1 - 3%, K2O 1 - 3%, Na2O 1 - 5%, Li2O 0 - 0.5% 。 5. The pore simulation generating agent according to claim 1, characterized in that, The pore simulation generating agent exists in a solid form when the temperature is lower than 60° C., has a melting point or a flammability point of 120-130° C., and has a high-temperature residual carbon content of less than 0.55% at 600° C.

6. A preparation method of a pore simulation generating agent as described in any one of claims 1 to 5, characterized in that, The method comprises: In parts by weight, 0-15 parts of urea and / or liquid paraffin, 10-30 parts of production powder, and 55-75 parts of specially prepared solid low-carbon fuel particles are weighed and mixed to form a dough; Pressing the dough into a thin cake using a double-roller compactor; After the thin cake is crushed, it is sieved through a 30-50 mesh screen to form solid dough particles, and the solid dough particles are used as a pore simulation generating agent.

7. A method for preparing a ceramic plate, characterized in that, The ceramic plate preparation method comprises: Obtain a pre-prepared base material, and mix the base material with the pore-simulating generating agent according to any one of claims 1 to 5 to obtain a shading powder; According to the preset digital fabric process requirements, add the shading powder into the corresponding material tank of the whole-body digital fabricator, and first perform reverse digital fabric on the steel belt of the whole-body digital fabricator to form a base material layer; Obtaining pre-prepared fabric, laying the fabric on the base material layer to form a fabric layer, drying to obtain a ceramic body, and sintering the ceramic body after treatment; In the drying process, the pore simulation generating agent is volatilized or decomposed into gas after combustion to form pores in the base material layer; in the firing process, the residual carbon after the combustion of the pore simulation generating agent is completely burned, and finally a ceramic plate with pore back pattern structural characteristics is obtained.

8. The method for preparing a ceramic plate according to claim 7, wherein A surface material layer is laid on the base material layer, and after drying, a ceramic body is obtained, comprising: A surface material layer is arranged on the base material layer, and drying is performed under the conditions of a drying temperature of 150-330° C. and a drying time of 65-95 minutes to obtain a ceramic green body.

9. The method for preparing a ceramic plate according to claim 7, wherein The firing temperature of the ceramic body is 1150-1220° C., and the firing time is 45-85 minutes.

10. A ceramic plate, characterized in that, The ceramic plate is prepared by the method for preparing a ceramic plate according to any one of claims 7 to 9.

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