A kind of prefabricated mould dry-pressing formed porcelain plate product and its manufacturing process

Abstract

The application discloses a kind of prefabricated mould dry-pressing porcelain plate product and its manufacturing process.The scheme includes flat blank layer and raised edge, flat blank layer and the raised edge are integrally dry-pressed by porcelain raw material, the height H1 of raised edge is 8mm~20mm, the thickness H2 of flat blank layer is 8mm~15mm;From the cross section of porcelain plate product, the angle α of the side of raised edge and vertical direction is ≥15°, the vertical projection of any edge of raised edge in flat blank layer does not overlap, raised edge includes at least two convex edges, the distance between convex edge and the side of porcelain plate product is 15mm~100mm, one side or both sides of convex edge is provided with lateral concave groove.The application solves the problem that the prior art cannot once-forming to make the porcelain plate product with the raised edge with the height of 8mm-20mm and the flat blank layer with the thickness of 8mm-15mm, and further can realize the technical effect that the plate is used for dry hanging more safely after secondary processing.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of architectural ceramics, in particular to a dry-pressed ceramic plate product and a manufacturing process thereof. BACKGROUND

[0002] With the development of building technology and materials, building curtain walls have been increasingly maturely applied to the interior and exterior walls of various buildings.

[0003] In terms of curtain wall materials, various aluminum plates, stone plates, ceramic plates, porcelain plates, glass plates, etc. are used. With the further improvement of demand, the market has higher requirements for the installation safety of curtain walls, the diversity of surface decoration effects of curtain wall materials, and the like. In addition, with the improvement of safety awareness in decoration applications, some specific applications require relatively higher firmness.

[0004] In order to achieve a comprehensive effect of the texture of the physicochemical properties of the material itself, the safety guarantee of the design of the material structure application, and the diversity of the material surface decoration effect, higher requirements are put forward for the plate and production.

[0005] The existing curtain wall method is mainly in the dry hanging mode, which fixes the plate on the wall through a hanging piece. Generally, various slotting methods, punching back bolt methods, etc. are used. These methods require certain damage to the plate itself through cutting and grinding, so the strength, hardness, and density performance of the plate itself are required to be higher, and must meet the standard requirements of relevant specifications.

[0006] When using the existing slotting or punching method on the plate itself, on the one hand, the plate itself needs to be thick and have high density and high strength and hardness to reduce the damage to the plate body caused by slotting or punching, thereby reducing the influence on safety, and on the other hand, the plate itself needs to be lighter to reduce the load of the curtain wall.

[0007] In the prior art curtain wall, in addition to the glass curtain wall, for example, the curtain wall panel of ceramic plate, aluminum plate, stone, artificial stone and the like, the ceramic plate mainly made of clay is formed by extrusion process and fired, and the highest temperature is generally 900-1100℃. The production efficiency of this process is very low, and it cannot reach the industrialized continuous mass production of tens of thousands of square meters or even hundreds of thousands of square meters per day per production line of building ceramics. It does not have the advantage of industrialized production. Moreover, the water absorption rate of the ceramic tile reaches more than 10%, and the thermal expansion and contraction changes greatly under the conditions of climate change in north and south regions, seasonal climate change and the like. Especially the high water absorption rate characteristics, in rainy and humid weather, the ceramic plate can easily absorb water and increase the weight, and even affect the performance, and also increase the load bearing of the wall structure. Moreover, the color of the ceramic plate is single, and there is almost no decorative effect on the surface except the body color. There is no rich and varied surface effect like the inkjet machine and supporting process of ceramic tile production line, which can almost restore various stone patterns, wood patterns, cloth patterns and other realistic arbitrary color patterns. Therefore, the extrusion process forming plate, especially the ceramic plate, has certain limitations in application performance and decorative effect, and needs to be improved.

[0008] For example, aluminum plate curtain wall, although light in quality, but the color is monotonous, the decoration is lack of richness, and needs to be improved.

[0009] For example, the stone curtain wall, because the stone itself is formed by natural resources, the color difference is difficult to unify, the texture is not the same, the porosity is more, and it needs to be waterproofed and protected, and needs a certain thickness to support the strength of use. But the increase of thickness also brings the increase of weight, so the physical and chemical properties have certain limitations. When used as dry hanging, the slotting and hole opening affect the strength more sensitively.

[0010] The prior art ceramic plate is pressed by a large tonnage press and sintered at a high temperature of 1150 DEG C or above, so its physical and chemical properties such as strength, hardness, acid and alkali resistance, and resistance to sudden cooling and heating are better than those of the ceramic plate and the stone. Therefore, it is a trend in the industry to use the ceramic plate as a dry hanging curtain wall. Moreover, the ceramic plate provided in the prior art is a conventional whole flat plate, and because the density of the ceramic plate blank after being pressed by a large tonnage and sintered at a high temperature is high, the mass of the flat plate per unit thickness and area is heavy, and the load of dry hanging is large. If the plate is too thin, the thickness of the corresponding position is reduced due to the grinding and cutting of the slotting and punching, so that the strength of the slotting and punching position is weakened, which causes a safety hazard. Therefore, in order to reduce the load and have a higher strength required by the standard, and also have a low water absorption rate of less than 3% or even less than 0.5%, the ceramic plate used for dry hanging curtain wall has become the direction of research and development of people in the industry.

[0011] However, the plate for curtain wall technology in the prior art, such as the technical solution of the "convex curtain wall plate" with the publication number CN110565853A, describes that the ceramic plate containing protruding blocks is integrally formed by using clay as the main raw material and adopting an extrusion process, and does not need to be processed by a plastic process again after being converted into a hard plate. This method for extrusion process is feasible for clay raw material, but the performance of the product of the clay process is limited as described above, and does not have the efficiency of industrialized continuous mass production, so the limitations of this process and product need to be improved. If the extrusion process is used for forming ceramic plate with porcelain clay raw material, there is no such technology in the prior art, because the plasticity cannot meet the requirements of clay raw material, and if the sintering temperature cannot reach 1150 DEG C-1220 DEG C, the formula raw material cannot be completely sintered, so this extrusion process integrally formed ceramic plate solution is limited and not feasible in the prior art.

[0012] In the prior art, there is also a technical solution such as the publication number CN101250930A (divisional application number 200510053355.8), which describes that a convex rib plate is made by using a predetermined design modeling grinding mold, which is completely different from the technical solution of integrally dry pressing the ceramic powder to form a plate containing protruding ribs with a height of not less than 8 mm and a plate blank thickness of not less than 8 mm.

[0013] Therefore, it is necessary to provide a ceramic plate suitable for dry hanging curtain wall or increasing the firmness of the ceramic plate. SUMMARY

[0014] To solve the above technical problems, the first object of the present application is to provide a prefabricated mold dry-pressed ceramic plate product, which comprises a flat blank layer and a raised ridge with a height of 8-20 mm dry-pressed integrally therewith, the raised ridge comprising at least two ridge bosses, and a lateral inner groove formed on both sides of the ridge bosses by secondary processing, and the raised ridge is firmly connected with a looped hanging piece, and the ceramic plate product is suitable for dry hanging of curtain walls and has the advantage of facilitating the enhancement of paving firmness.

[0015] To achieve the above-mentioned objects, the technical solutions adopted by the present application are as follows:

[0016] A prefabricated mold dry-pressed ceramic plate product, which comprises a flat blank layer and a plurality of raised ridges, the flat blank layer and the raised ridges being integrally dry-pressed from a ceramic raw material, the height H1 of the raised ridges being 8-20 mm, and the thickness H2 of the flat blank layer being 8-15 mm.

[0017] From the cross section of the ceramic plate product, the angle a between the side surface of the raised ridge and the vertical direction is greater than or equal to 15°, the vertical projection of any edge of the raised ridge on the flat blank layer does not overlap, the raised ridge comprises at least two ridge bosses, the ridge bosses are in the shape of a long strip, the ridge bosses are parallel to each other and parallel to one of any two mutually parallel edges of the ceramic plate product, the minimum parallel distance B between the ridge bosses and the closest side edge of the ceramic plate product is 15-100 mm, and a lateral inner groove is arranged on one side or both sides of the ridge bosses.

[0018] By such arrangement, the ceramic plate product is easy to demold, the pressing density is easy to be uniform within a certain range, and the product is easy to be formed by firing, which are important research points. To obtain the ceramic plate product, innovative design is made on the pressing machine mold, and thousands of experiments and modification of mold parameters are carried out. The plasticity of the raw material formula, physical drainage, structural drainage, oxidation exhaust, and drying and firing system design matching are matched, so that the product and method of the present application are realized. For example, the height of the raised ridge is 8-20 mm, the thickness of the flat blank layer is 8-15 mm, the angle a between the side surface of the raised ridge and the vertical direction is greater than or equal to 15°, and the vertical projection of any edge of the raised ridge on the flat blank layer does not overlap. These designs are comprehensive and synergistic, which ensure easy demolding during pressing.

[0019] It is well known in the industry that since the rise of porcelain tiles in China in the last century, technology has been developing and progressing. In the production process of such porcelain tiles, not only are various concave-convex patterns designed on the back, but also various concave-convex mold patterns are designed on the surface of the porcelain tiles. These mold patterns are integrally formed. Therefore, the integrally formed mold-shaped body product has been a technical solution since before the year 2000. Therefore, the integrally formed modeling ideas of the technical solutions of the above-mentioned publication number CN110565853A and publication number CN101250930A (division application number 200510053355.8) are not novel proposals. They are only existing technologies and earlier technical solutions that do not have a breakthrough in the depth of the concave-convex mold pattern. This is a problem of existing technologies. Therefore, the convex rib of the existing product concave-convex pattern has a height of not less than 8 mm, and the innovative solution of the convex rib after design and secondary processing can be used for dry hanging applications. Because the porcelain raw material is used and a three-thousand-ton press is used to press the porcelain plate body containing the convex rib, the objective problem of easy demolding after pressing needs to be solved. The problem of the adaptation of the firing process of drainage, oxidation, exhaust, and shrinkage during firing also needs to be considered. Only after these technical problems are solved, can the integrally formed porcelain plate body containing a convex rib with a height of not less than 8 mm and a flat plate body thickness of not less than 8 mm become feasible. And after the secondary processing of the corresponding convex rib to form a lateral recess on the rib side, the porcelain plate body required for firm and reliable dry hanging can become feasible. The lateral recess on the convex rib side is designed to reduce the damage caused by directly slotting and punching in the flat plate body. The remaining convex rib is designed to better increase the strength of the plate.

[0020] The definition of 8 mm rib height and flat body layer thickness is designed in combination with actual application. Because the rib height is less than 8 mm, the strength is not high after the secondary processing of slotting on the rib side, and the size of the slotting is limited. The flat body layer with a thickness of less than 8 mm has weak wind pressure resistance in dry hanging applications, which poses a safety hazard.

[0021] This comprehensive design innovation solves the problem of the existing technology that cannot produce a porcelain plate product with a convex rib height of 8 mm-20 mm and a flat body layer thickness of 8 mm-15 mm. It also further achieves the technical effect of using this plate for safer dry hanging after secondary processing. This is another place where the invention is creative and practical.

[0022] As a preferred embodiment, the height H1 of the convex rib is 8 mm-15 mm, and the thickness H2 of the flat body layer is 8 mm-13 mm.

[0023] As a preferred embodiment, the angle α between the side surface of the convex rib and the vertical direction is ≥20°.

[0024] Preferably, the top of the convex ridge is provided with a recess, the depth of which is not more than H1 / 2.

[0025] By such an arrangement, the design is equivalent to pressing down the middle of the same volume of single ridge to increase the density of the ridge, which is one of the effective means to adjust the density of the convex ridge. The recess with a depth not more than half the height of the ridge at the top of the convex ridge near the two sides is designed to keep the top of the ridge at the required height, while the overall powder is compacted more tightly so that the green density of the ridge can be adjusted and controlled consistently. The matching design of the parameters such as angle, ridge height, recess design on the ridge, and spacing can effectively adjust the technical problems of demoulding and density uniformity, so that the production of ceramic green body products with a convex ridge height of 8-20 mm and a flat green layer thickness of 8-15 mm can be realized.

[0026] Preferably, the spacing C of the top of each convex ridge on both sides is not less than 3 mm.

[0027] By such an arrangement, the convex ridge can ensure that the ceramic product has sufficient strength and can support the plate during transmission in the roller kiln, avoiding the occurrence of sharp end damage.

[0028] Preferably, the spacing A of each convex ridge on both sides at the position of H1 / 2 is 15-70 mm.

[0029] By such an arrangement, this is a specific design of widened ridge that can be used for secondary processing to produce a side inward groove that can be buckled and hung, and the widened design greatly ensures the strength for dry hanging.

[0030] Preferably, from the cross section of the ceramic plate product, the intersection of the side edges of the two adjacent convex ridges and the flat green layer coincides or is 3-10 mm apart.

[0031] By such an arrangement, this design is to make the reverse designed pressing die easily and effectively collect the raw material in the gap interval during the pressing process, so that the density distribution of the raw material in the ridges and the flat green layer is uniform within a certain range that can be demoulded and not cracked, which is also achieved through hundreds of tests on the flowability of ceramic powder, detection of density, adjustment of roller height, angle, and other parameters.

[0032] Preferably, the surface of the ceramic plate product away from the convex ridge is a plane or contains a recessed texture with a depth of 0.5-5 mm.

[0033] By such an arrangement, the richness of the surface decoration three-dimensional effect is increased.

[0034] Preferably, the surface of the ceramic plate product away from the raised ridge is a ceramic body surface or a decorative layer containing an inkjet pattern and glaze, dry granular material.

[0035] Preferably, the ceramic plate product is a conventional ceramic body or a ceramic light body with a water absorption of <0.5% and a density of 1.75-1.9 g / cm 3 .

[0036] Based on the same inventive concept, a second object of the present application proposes a manufacturing process for a ceramic plate product formed by dry pressing a preform mold, comprising the following steps:

[0037] Step 1: First, prepare the body bottom mold of the ceramic press according to the reverse design of the ceramic plate product described above, and prepare the body surface mold according to the reverse design of the plane or concave-convex shape as the upper and lower molds required for pressing, and install them on the press of the production line;

[0038] Step 2: Prepare the ceramic raw materials for producing ceramic tile products;

[0039] Step 3: Lay the ceramic raw materials of the required thickness evenly through the material grid to the pressing position of the press;

[0040] Step 4: Press and form into a body;

[0041] Step 5: Adjust the direction so that the straight ridge of the body is perpendicular to the conveying direction, and then enter the drying kiln for drying and the firing kiln for firing at a maximum temperature of 1150-1220°C to become a semi-finished body;

[0042] Step 6: Cool, edge grinding, and obtain the semi-finished product of the ceramic plate product;

[0043] Step 7: On one side or both sides of the raised ridge of the semi-finished product of the ceramic plate product, use a predetermined processing tool to process and grind to form a predetermined shape and depth of the lateral recess.

[0044] Preferably, the press in Step 1 is a punch press, a roller press, or a top press dry pressing press.

[0045] Preferably, the ceramic raw material uses conventional ceramic powder with a water content of less than 9%.

[0046] Preferably, the body bottom mold and the body surface mold are designed in reverse according to the corresponding body bottom and body surface of the ceramic plate product described above and combined with the pressing and shrinkage of the ceramic tile, i.e., the ceramic plate product and the body bottom mold, and the ceramic plate product and the body surface mold are a matched mold of one male and one female.

[0047] As preferred, the press-molded body is first subjected to the glazing line process for inkjet and application of glaze and dry granular material surface decoration layer of predetermined pattern after entering the drying of step five, and then enters the firing kiln process.

[0048] As preferred, step three can also be to pre-press the predetermined porcelain powder into a shape matching the base mold design using a smaller pressure or pre-forming the raw material into a shape matching the base mold design using a rake method, and then using the press mold of step one to press-form the body, i.e., step four.

[0049] By such arrangement, the porcelain plate material with a height of 8-20 mm protruding ridge and a flat body layer thickness of 8-15 mm is formed by at least 3,000 tons of large-tonnage press molding of porcelain raw materials, and the predetermined protruding ridge of the plate material is subjected to secondary processing of slotting on both sides, thereby obtaining a porcelain plate material with lightweight design and predetermined coarse ridge side processing forming an inner groove for securely fitting and hanging the curtain wall dry hanging application, and the present application uses porcelain raw materials for dry pressing, which cannot be achieved by extrusion process, and cannot be directly applied to porcelain plate material process by extrusion process.

[0050] Compared with the prior art, the present application has the beneficial technical effects:

[0051] 1、The innovative design of the present application, which is a kind of pre-mold dry-pressed porcelain plate product and the at least two sides of the at least two platform ridges on the back of the product are subjected to slotting processing to form predetermined shape and size of the lateral inner groove, can make the metal profile be fitted into the lateral inner groove of the protruding ridge, thereby making the porcelain plate material more safely applied to the curtain wall dry hanging through the hanging piece, because the stress direction of the dry hanging curtain wall is the vertical up and down force, so the stress of the line and surface after the groove is fitted is firm and reliable, and the bolt member can be used to reinforce the fitting part to make the fitting part as a whole to protect the protruding ridge, which is more firm; and since the plate material of the present application is dry-pressed by flat body layer and protruding ridge, it has the characteristics of high strength and good integration; thereby providing a better physical and chemical performance, safer dry hanging curtain wall material selection for the dry hanging application of building curtain wall.

[0052] 2. The ceramic plate product of the present application is characterized in that the protruding ribs on the back of the product are designed to be spaced apart. Compared with a solid flat blank body of the same thickness without protruding ribs, the product of the present application greatly saves the weight of the blank body without sacrificing the effect and strength. For example, when the flat layer blank body is 1 cm, the protruding rib is 1.3 cm, the angle between the side of the protruding rib and the vertical direction is 33°, and the intersection of the protruding rib and the bottom surface is intersected, the weight of the blank body can be saved by about one quarter. This will produce more beneficial effects, one of which is that the load for dry hanging is reduced, two of which are that the raw materials for making the product are saved, three of which are that the energy consumption for firing the product is saved, and four of which are that the transportation weight is saved. Such reduction in load and cost saving; five, when the product of the present application is applied to light ceramic blank body, the advantages of the product of the present application combined with light ceramic blank body will further greatly reduce the load.

[0053] 3. The ceramic plate product of the present application is characterized in that the ceramic plate product of the present application is a ceramic product production field. The production technology of ceramic tiles in the prior art is very mature. Therefore, the reproducibility of the present application is very good. By using the existing ceramic tile production technology, the surface of the product of the present application is sprayed with ceramic color ink by a ceramic inkjet machine to form a predetermined color pattern, and then glaze, dry particles and other materials are applied to perform surface decoration effect treatment. The surface of the product can be made to have a variety of materials such as natural stone, wood grain, cloth grain and the like by scanning to form data information and pattern files, and then the ceramic inkjet machine is used to spray and print the digital inkjet texture pattern on the surface of the product to form a variety of effects. This will provide a plate product with safer dry hanging design structure, more diverse surface effects and higher physical and chemical properties for curtain wall dry hanging. This ceramic tile process using a ceramic inkjet machine to perform inkjet treatment to form a variety of color patterns and industrialized mass production can meet the increasing demand for aesthetic needs and safety performance, which cannot be matched by the monotonous color of the extrusion process and cannot be achieved by the extrusion process.

[0054] 4. The ceramic plate product of the present application is characterized in that the production process of ceramic tiles is adopted to produce a color full-body blank effect by mixing materials, and a color inkjet pattern effect on the surface, as well as decoration after applying various degrees of glaze and dry particles, to form a variety of blank body and surface decoration effects. This not only provides a better plate for curtain wall dry hanging, but also can be used for lower wall sticking and floor paving applications. The design of the protruding ribs also greatly increases the bonding force between the adhesive material and the plate ribs, so the paving application is more firm.

[0055] 5、The production process of the ceramic plate product of the prefabricated mold dry pressing forming of the application, is through the innovative design and preparation of the mold, the matching control of the raw material formula, the matching of the press, the design of the appropriate drying and kiln firing system, and can realize industrialized mass production in the production line process of the ceramic tile. Compared with the efficiency of the extrusion process, it is greatly improved.

[0056] 6、The production process of the ceramic plate product of the prefabricated mold dry pressing forming of the application, through the innovative design and preparation of the mold, realizes the effect of pressing the flat material to produce the predetermined design convex edge product. It is well known in the industry that flat material is the most efficient and simple material in the production process of ceramic tiles. The innovative design of the application meets the requirement of one-time material forming of the predetermined shape, which not only produces the predetermined innovative design effect, but also reduces the difficulty of production technology and improves the efficiency. BRIEF DESCRIPTION OF DRAWINGS

[0057] Figure 1 It is a three-dimensional design drawing of the pressing and forming body and the matching mold of the prefabricated mold dry pressing forming of the ceramic plate product of the application.

[0058] Figure 2 It is a cross-sectional schematic view of the pressing and forming body and the matching mold of the prefabricated mold dry pressing forming of the ceramic plate product of the application.

[0059] Figure 3 It is a local enlarged schematic view of the pressing and forming body of the prefabricated mold dry pressing forming of the ceramic plate product of the application.

[0060] Figure 4 It is a schematic diagram of the installation of the production line of the prefabricated mold dry pressing forming of the ceramic plate product of the application.

[0061] Figure 5 It is a three-dimensional schematic view of the prefabricated mold dry pressing forming of the ceramic plate product of the application.

[0062] Figure 6 It is a schematic view of the surface of the prefabricated mold dry pressing forming of the ceramic plate product of the application containing inkjet texture.

[0063] Figure 7 It is a cross-sectional schematic view of the prefabricated mold dry pressing forming of the ceramic plate product of the application after secondary processing of the predetermined convex edge.

[0064] Among them, the technical features referred to by each figure mark are as follows:

[0065] 11, pressing and forming body; 12, base mold; 21, convex edge; 22, flat blank layer; 31, raw material conveying device; 32, press; 33, conveying roller table; 3111, hopper; 3112, material collecting hopper; 41, convex edge; 42, lateral inner groove. DETAILED DESCRIPTION

[0066] In order to make the objectives, technical solutions and advantages of the present application clearer, the present application will be further described in detail below with reference to examples, but the scope of protection claimed by the present application is not limited to the following specific examples.

[0067] Example One

[0068] With reference to Figure 1 , Figure 2 , Figure 3 and Figure 5 , the present example discloses a ceramic plate product formed by preform dry pressing, comprising a flat blank layer and a raised ridge, the flat blank layer and the raised ridge are integrally dry-pressed from a ceramic raw material, the height H1 of the raised ridge is 8mm-20mm, and the thickness H2 of the flat blank layer is 8mm-15mm.

[0069] From the cross section of the ceramic plate product, the angle α between the side surface of the raised ridge and the vertical direction is ≥15°, the vertical projection of any edge of the raised ridge on the flat blank layer does not overlap, the raised ridge comprises at least two ridge bosses, the ridge bosses are in a strip shape, the ridge bosses are parallel to each other and parallel to one of the two parallel edges of the ceramic plate product, the minimum parallel distance B between the ridge bosses and the adjacent side edge of the ceramic plate product is 15mm-100mm, and a lateral inner groove is arranged on one side or both sides of the ridge boss, the lateral inner groove is formed by secondary processing, and whether the lateral inner groove is arranged on both sides of the ridge boss is selected according to actual needs.

[0070] The height H1 of the raised ridge is 8mm-15mm, preferably, H1 can be selected as 8.5mm, 9mm, 9.5mm, 10mm, 10.5mm, 11mm, 11.5mm, 12mm, 12.5mm, 13mm, 13.5mm, 14mm or 14.5mm, and the thickness H2 of the flat blank layer is 8mm-13mm, preferably, H2 can be selected as 8.5mm, 9mm, 9.5mm, 10mm, 10.5mm, 11mm, 11.5mm, 12mm, 12.5mm.

[0071] Preferably, the angle α between the side surface of the raised ridge and the vertical direction is ≥20°.

[0072] Preferably, a recessed part is arranged on the top of the ridge boss, and the depth of the recessed part is not more than H1 / 2.

[0073] Preferably, with reference to Figure 2 , the distance A between the two sides of each ridge boss at the position of H1 / 2 is 15mm-70mm.

[0074] Preferably, with reference to Figure 2The distance C between the top of each raised ridge on both sides is not less than 3mm, and the top of the raised ridge is connected by a circular arc.

[0075] Preferably, the intersection of the side edges of two adjacent raised ridges and the flat layer of the ceramic plate product is coincident or spaced apart by 3mm-10mm.

[0076] Preferably, the surface of the ceramic plate product away from the raised ridges is a plane or contains a concave-convex texture with a depth of 0.5mm-5mm.

[0077] Preferably, the surface of the ceramic plate product away from the raised ridges is a ceramic body surface or contains a decorative layer of inkjet patterns and glaze, dry granular material.

[0078] Preferably, the ceramic plate product is a conventional ceramic body or a ceramic light body with a water absorption of <0.5% and a density of 1.75-1.9g / cm 3 .

[0079] Example Two

[0080] The present embodiment discloses a process for manufacturing a preform mold dry-pressed ceramic plate product, which is applied to the manufacture of the preform mold dry-pressed ceramic plate product of Example One, and comprises the following steps:

[0081] Step One: design the shape of the product, match the plasticity of the raw material formula, the physical drainage of drying, the structural drainage, and the drying and firing system of oxidation and sintering, and design the shrinkage rate of the ceramic tile pressing and forming, thereby designing the parameters of the pressing and forming body 11, and then reversely designing the body bottom mold 12 of the ceramic pressing machine, as shown in Figure 1 , Figure 2 The height H1 of the raised ridge 21 of the pressing and forming body is set to 13mm, the thickness of the flat layer 22 of the pressing and forming body is set to 11mm, and the included angle a between the side edge of the raised ridge and the vertical direction is set to 32°, as shown in Figure 3 ;

[0082] Design the body surface mold with a flat surface or a concave-convex texture with a depth of 0.5mm-5mm (not labeled in the figure);

[0083] Install the body bottom mold and the body surface mold on the pressing machine 32 of the production line;

[0084] Step Two: prepare the conventional ceramic raw material for the production of ceramic tile products;

[0085] Step Three: start the production equipment, the discharge hopper 3111 on the raw material conveying device 31 drops the loaded raw material onto the material collecting hopper 3112, which includes a material distribution grid, and the raw material is evenly filled into the mold cavity of the pressing machine 32 through the material distribution grid;

[0086] Step four: the green body is formed by the press die described in step one and sent to the next process by the conveying roller table 33, as shown in Figure 4 ;

[0087] Step five: adjust the direction so that the straight protruding edges of the green body are perpendicular to the direction of entering the drying kiln and the firing kiln with the highest temperature of 1150-1220°C to be fired into a semi-finished green body;

[0088] Step six: cooling, edge grinding, and obtaining the porcelain plate product of the preform die dry pressing forming of the application, as shown in Figure 5 ;

[0089] In order to better increase the strength of the edges, in actual implementation, for the edge height of 8-20mm and the flat green layer thickness of 8-15mm, the ratio of the edge height to the flat green layer thickness is 1:1-1.5:1.

[0090] Preferably, in step one, the press can be selected as a punching type, a roller pressing type or a top pressing type dry pressing forming press.

[0091] Preferably, in step two, the porcelain raw material uses conventional porcelain powder with a water content of less than 9%.

[0092] The green bottom die and the green surface die are respectively designed in reverse according to the corresponding green bottom and green surface modeling of the porcelain plate product and the shrinkage rate of the porcelain tile pressing forming, that is, the porcelain plate product and the green surface die, and the porcelain plate product and the green bottom die are one male and one female matching modeling.

[0093] Example three

[0094] Based on example two, in step five, after drying in the drying kiln and before firing in the firing kiln, the surface decoration layer treatment of the predetermined pattern inkjet and glaze dry particle process is carried out in the glazing line process, and finally the porcelain plate product of the preform die dry pressing forming of the application containing the inkjet texture on the surface is obtained, as shown in Figure 6 .

[0095] Example four

[0096] Based on the above examples, on one side or both sides of the protruding edge of the preform die dry pressing formed porcelain plate product finally obtained, according to the matching of the dry hanging profile, a predetermined machining tool is used for secondary processing to form a predetermined shape and depth of the concave groove, that is, a preform die dry pressing formed porcelain plate product is obtained and its predetermined protruding edge on the back is an inner groove with a firmly sleeved hanging part, as shown in Figure 7 . The protruding edge 41 is machined to form a lateral concave groove, so that the protruding edge 41 is in the shape of a dovetail groove.

[0097] Example five

[0098] Based on the above embodiments, step three can also be to first pre-press the predetermined porcelain powder into a shape matching the base mold design using a smaller pressure or a combing method, and then press the pre-pressed shape into a green body using the press mold designed in step one, i.e. step four.

[0099] According to the disclosure and teachings of the above specification, those skilled in the art can make changes and modifications to the above embodiments. Therefore, the present application is not limited to the specific embodiments disclosed and described above, and some modifications and changes to the application should fall within the protection scope of the claims of the present application. In addition, although some specific terms are used in the specification, these terms are only for convenience of description and do not constitute any limitation on the application.

Claims

1. A pre-molded ceramic slab product, comprising a flat layer and several raised ridges, characterized in that, The flat layer and the raised ridge are integrally dry-pressed from ceramic raw material. The height H1 of the raised ridge is 8mm~15mm, and the thickness H2 of the flat layer is 8mm~13mm. From the cross-section of the ceramic slab product, the angle α between the side of the raised edge and the vertical direction is ≥20°, the vertical projection of any side of the raised edge on the flat layer does not overlap, the raised edge includes at least two boss edges, the boss edges are elongated, the boss edges are parallel to each other and the boss edges are parallel to one of any two parallel sides of the ceramic slab product, the minimum parallel distance B between the boss edge and the nearest side of the ceramic slab product is 15mm~100mm, and a lateral inward groove is provided on one or both sides of the boss edge. The top of the boss edge is provided with a recessed portion, and the depth of the recessed portion does not exceed H1 / 2.

2. The ceramic slab product formed by dry pressing with a prefabricated mold according to claim 1, characterized in that, The distance C between the top two sides of each of the protruding ridges is not less than 3 mm.

3. The ceramic slab product formed by dry pressing with a prefabricated mold according to claim 2, characterized in that, The distance A between the two sides of each boss edge at position H1 / 2 is 15mm to 70mm.

4. The ceramic slab product formed by dry pressing with a prefabricated mold according to claim 3, characterized in that, When viewed from the cross-section of the ceramic slab, the intersection of the two adjacent raised edges with the flat blank layer coincides or is 3mm to 10mm apart.

5. The ceramic slab product formed by dry pressing with a prefabricated mold according to claim 1, 2 or 4, characterized in that, The surface of the ceramic plate product facing away from the raised edge is either flat or contains textured surfaces with a depth of 0.5mm to 5mm.

6. The ceramic slab product formed by dry pressing with a prefabricated mold according to claim 1, 2 or 4, characterized in that, The surface of the ceramic plate product facing away from the raised edge is a ceramic blank or a decorative layer containing inkjet patterns, glaze, or dry granular materials.

7. The ceramic slab product formed by dry pressing with a prefabricated mold according to claim 1, 2 or 4, characterized in that, Porcelain slab products are made of conventional porcelain blanks or have a water absorption rate of <0.5% and a density between 1.75 and 1.9 g / cm³. 3 The porcelain body is lightweight.

8. A manufacturing process for pre-formed ceramic slab products by dry pressing, characterized in that, It includes the following steps: Step 1: First, prepare the blank bottom mold of the ceramic press according to the reverse design of the ceramic slab product as described in any one of claims 1 to 7, and prepare the blank surface mold according to the reverse design of the plane or concave-convex shape, as the upper and lower molds required for pressing, and install them on the press of the production line. Step 2: Prepare the porcelain raw materials for producing porcelain tiles; Step 3: Spread the ceramic raw material of the required thickness evenly onto the pressing position of the press through the fabric grid; Step 4: Press and shape into a blank; Step 5: Adjust the direction so that the straight raised edges of the billet are perpendicular to the conveying direction before entering the drying kiln for drying and firing in the firing kiln at a maximum temperature of 1150℃-1220℃ to become a semi-finished billet. Step 6: Cooling and edge trimming to obtain a semi-finished ceramic slab product; Step 7: On one or both sides of the raised edge of the obtained ceramic slab semi-finished product, a lateral inner groove of a predetermined shape and depth is formed by secondary processing and grinding using a predetermined processing tool.

9. The manufacturing process according to claim 8, characterized in that, The press mentioned in step one is a stamping, rolling, or top-pressing dry pressing press.

10. The manufacturing process according to claim 8, characterized in that, The ceramic raw material is a conventional ceramic powder with a moisture content of less than 9%.

11. The manufacturing process according to claim 8, characterized in that, The blank base mold and blank surface mold are designed in reverse according to the corresponding blank base and blank surface shapes of the porcelain slab products as described in any one of claims 1 to 7, combined with the pressing and shrinkage rate of porcelain tiles. That is, the porcelain slab products and blank base molds, and the porcelain slab products and blank surface molds are all matched with each other in a male-female pair.

12. The manufacturing process according to claim 8, characterized in that, After the pressed and shaped blank enters the drying process in step five, it first enters the glaze line process to perform inkjet printing of the predetermined pattern and the application of glaze and dry granule material surface decoration layer, and then enters the firing kiln process for firing.

13. The manufacturing process according to claim 8, characterized in that, Step three can also be to first pre-press the predetermined porcelain powder with a smaller pressure according to the design or to pre-shape the raw material into a shape that matches the shape of the blank mold using a combing method, and then press it into a blank using the press mold designed in step one, which is step four.

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