A ceramic plate formed by one-time dry pressing of a prefabricated mold and a manufacturing method thereof

Abstract

The present invention discloses a porcelain plate formed by one-time dry pressing of a prefabricated mold and a manufacturing method thereof. The solution includes a flat blank layer and a prefabricated protrusion. The flat blank layer and the prefabricated protrusion are integrally dry pressed from porcelain raw materials. The height H1 of the prefabricated protrusion is 8 mm to 20 mm, and the thickness H2 of the flat blank layer is 6 mm to 15 mm. This porcelain plate can be used for safer curtain wall dry hanging through hanging parts, and is integrally dry pressed with the flat blank layer and the prefabricated protrusion, having the characteristics of high strength and good integrity; thus providing a choice of curtain wall material with better physical and chemical properties and safer dry hanging for the dry hanging application of building curtain walls.

Description

Technical Field

[0001] The invention relates to the field of building ceramics, and in particular to a ceramic plate formed by one-time dry pressing of a prefabricated mould and a manufacturing method thereof. Background Art

[0002] With the development of construction technology and materials, building curtain walls have been increasingly used in the interior and exterior walls of various buildings.

[0003] In terms of curtain wall materials, various types of aluminum plates, stone plates, ceramic plates, porcelain plates, glass plates and other building plates are used. In the selection of these building plates, with the further improvement of application needs and requirements, the market has put forward higher requirements on the installation safety, construction convenience, efficiency and diversity of surface decoration effects of curtain wall materials, and is developing towards prefabricated applications; in addition, with the improvement of safety awareness in decoration applications, in addition to the firmness and high safety of curtain wall dry hanging applications, the application of plate pasting also requires higher firm adhesion.

[0004] In order to achieve the comprehensive effect of the physical and chemical properties of the curtain wall panels themselves, the design of the safety assurance of the material structure application, and the diversity of the material surface decorative effects, higher requirements are placed on the panels and their production.

[0005] The mainstream curtain wall method in the existing technology is mainly dry hanging, in which the panels are fixed to the wall by hangers. The keels generally have various slotted, punched and bolted methods. These methods require cutting and grinding of the panels themselves, which causes certain damage, so the strength, hardness and density of the material itself are required to be relatively high.

[0006] When the existing method of grooving or punching holes in the plate itself is used for construction, on the one hand, it is hoped that the plate itself is thick and has high density, high strength and hardness to reduce the damage to the plate body caused by grooving and punching, thereby reducing the impact on safety. On the other hand, it must have high strength to enhance wind resistance. On the other hand, it is also hoped that it has good physical and chemical properties to enhance weather resistance to reduce the impact of climate on the material. It is also hoped that the plate itself is lighter in weight to reduce the load on the curtain wall.

[0007] In the existing curtain wall technology, in addition to the most common glass curtain wall, there are curtain wall panels such as ceramic panels, aluminum panels, stone panels, artificial stones, etc., which are mainly made of clay. Because it is mainly made of clay through a semi-wet mud-like material extrusion process and fired, the highest temperature is generally 900-1100℃. The extrusion process of this mud-like raw material is completely different from the dry pressing of fluid powdery granular ceramic raw materials into ceramic panels and then fired at a maximum temperature of 1150-1220℃. The production efficiency is very low and cannot be compared with the industrial continuous mass production of building ceramics, where each production line can reach tens of thousands or even tens of thousands of square meters per day. It has shortcomings in industrial production to manufacture products; and the water absorption rate of this ceramic brick is more than 10%, which is very low in the climate of the north and south regions. The clay board has a large change in color, thermal expansion and contraction under seasonal climate changes, and the change is large, especially the high water absorption rate. It is easy to absorb moisture in humid weather such as rain, which increases the load of the clay board and even affects the performance. This makes the load-bearing of the wall structure on rainy days and sunny days vary greatly. Moreover, this kind of clay board has a single color. In addition to the color of the body, it has almost no decorative effect on the surface, let alone the rich and diverse surface effects of the inkjet machine and supporting process of the ceramic tile production line that can almost restore various realistic color patterns of stone, wood, cloth, etc. Therefore, the extrusion process formed board, especially the clay board, because of the physical and chemical properties of its own material and the characteristics of its extrusion process, it still has limitations in the performance of weather-resistant applications and decorative effects, which need to be improved.

[0008] However, aluminum panel curtain walls, although light in weight, have monotonous colors and lack of decorative richness, which needs to be improved.

[0009] For example, stone curtain walls, because stone itself is formed by natural resources, it is difficult to unify the color difference, the texture is different, there are many pores, the density is uneven or even loose, so it needs to be waterproofed and has a certain thickness to support its strength. However, the increase in thickness also brings about an increase in load, so its physical and chemical properties have certain limitations. When used for grooving and hole opening during dry hanging, its strength is more sensitive to influence.

[0010] The ceramic plates in the prior art are pressed by a large-tonnage press and fired at a high temperature of more than 1150°C. Therefore, they are better than ceramic plates and stone materials in terms of physical and chemical properties such as bending wind resistance, hardness, acid and alkali resistance, density, anti-fouling, and thermal stability against rapid cooling and heating. Therefore, it is a trend in the industry to use ceramic plates for curtain wall dry hanging. However, the ceramic plates that can be provided for curtain wall applications in the prior art are all conventional integral flat plates. Because the density of the ceramic plate blanks is high after large-tonnage pressing and high-temperature sintering, the mass of the flat plate per unit thickness and area is heavier, and the load on dry hanging is greater. If it is too thin, when the slotting and punching method is used for dry hanging, the grinding and cutting of the slotting and punching will make the thickness of the corresponding position thinner than that of other flat plate blanks, thereby weakening the strength of the slotting and punching positions and bringing safety hazards. Therefore, in order to reduce the load and have the higher flexural and wind resistance strength required to meet the standards, ceramic panels with low water absorption of less than 3% or even less than 0.5% are used for dry hanging of curtain walls, which has become the research and development direction of industry insiders.

[0011] Among the existing panels used in curtain wall technology, there is a technical solution of "a convex curtain wall panel" with a publication number of CN110565853A, which describes a method of using clay as the main raw material to form an integral part by an extrusion process to produce an integral ceramic panel containing a convex clamping block without the need for secondary processing of a plastic process after it is converted into a hard panel. This method for the extrusion process is feasible for using clay raw materials, but the performance of the products of the clay process has been described in the above of the present invention, and it has limitations, and the extrusion process does not have the advantages of only 40 minutes for the current production of 800*800mm*10mm porcelain tiles. The efficiency of industrial continuous mass production, for example, can be completed in just 1 minute, so the limitations of this process and products need to be improved; and if porcelain clay raw materials are used for extrusion molding, the prior art has not seen it, because its plasticity does not meet the requirements of clay raw materials, and if the firing temperature does not reach 1150°C-1220°C, the formula raw materials cannot achieve the complete sintering of powdery and granular porcelain raw materials with a content of more than 16% alumina, more than 62% silicon dioxide, and more than 2% potassium and sodium oxides after firing. Therefore, this extrusion process integrated molding of porcelain raw material plate technical solution is limited in the prior art, and there is no actual product that has been truly realized.

[0012] In the prior art, there are also technical solutions such as the publication number CN101250930A (divisional application number 200510053355.8), which describes the use of a predetermined design and shape of polishing molds to cut and polish to produce convex ridged plates, which is a secondary processing of the pressed and fired porcelain plates. This is completely different from the design of using porcelain powder to form a plate with prefabricated protrusions of not less than 8mm in height and a flat plate body thickness of not less than 6mm by integrated dry pressing.

[0013] Therefore, it is necessary to propose a solution for a porcelain plate suitable for dry-hanging curtain walls or for increasing the firmness of paving. Summary of the invention

[0014] In order to solve the above technical problems, the first purpose of the present invention is to provide a ceramic plate formed by one-time dry pressing of a prefabricated mold, which includes a flat layer with a thickness of not less than 6 mm and prefabricated protrusions with a height of 8-20 mm formed integrally with it by dry pressing. This ceramic plate is suitable for use in dry hanging of curtain walls and has the advantages of strong laying firmness and high flexural strength.

[0015] In order to achieve the above-mentioned invention object, the technical solution adopted by the present invention is as follows:

[0016] A ceramic plate formed by one-step dry pressing of a prefabricated mold, comprising a flat blank layer and a plurality of prefabricated protrusions provided in advance, wherein the flat blank layer and the prefabricated protrusions are integrally formed by dry pressing of a ceramic raw material, wherein the height H1 of the prefabricated protrusions is 8 mm to 20 mm, and the thickness H2 of the flat blank layer is 6 mm to 15 mm;

[0017] Viewed from the cross section of the porcelain plate, the angle α between the side surface of the prefabricated protrusion and the vertical direction is ≥15°, and the vertical projections of any edges of the prefabricated protrusion on the surface plane of the flat green sheet do not overlap.

[0018] Through such a setting, the porcelain plate is easy to demould, and the pressing density is easy to be uniform within a certain range, which is conducive to firing and forming. In order to obtain the porcelain plate, the press mold shape and parameters such as depth, shallowness, length and shortness are innovatively designed, and thousands of experiments and mold parameter modifications are carried out. The plasticity of the raw material formula, the physical drainage of drying, the structural drainage, the oxidation exhaust and the design and matching of the drying and firing system of sintering are matched, so as to realize the product and method of the present invention. For example, the height of the prefabricated protrusion is 8mm to 20mm, the thickness of the flat blank layer is 6mm to 15mm, the angle α between the side edge of the prefabricated protrusion and the vertical direction is ≥15°, and the vertical projection of any edge of the prefabricated protrusion on the flat blank layer does not overlap. These designs are comprehensive and coordinated to ensure that the molding and easy demoulding can be achieved during pressing;

[0019] It is well known in the industry that since the rise of porcelain vitrified tiles in China in the last century, the technology has been developing and improving. In the production process of this kind of porcelain tiles, not only are various concave and convex patterns designed on the back, but also various concave and convex mold shapes are designed on the surface of the porcelain tiles. These mold shapes are all integrally formed. Therefore, the green product of the one-piece molding mold brick shape is a technical solution that existed before 2000 AD. Therefore, the above-mentioned publication number CN110565853A, publication number CN101250930A (divisional application number 200510053355.8), and the technical solution of the prior application of the applicant with application number 2020100361838 on January 14, 2020, are not proposals that affect the novelty of this case, but are only existing technologies and earlier technical solutions. The following problems still exist in the existing technology: there has been no deeper breakthrough in the depth of the depression of the concave and convex mold shape made by dry pressing of powdery ceramic raw materials, or further solutions are needed to solve the problems of high flexural strength and non-cracking in molding, as well as the use of products of this design.

[0020] Therefore, the convex and concave ridges of the prior art products other than those of the inventor do not have prefabricated protrusions with a height of not less than 8 mm, and after design and secondary processing, they are innovative solutions that can be used for dry hanging applications, or the prior application of the applicant with application number 2020100361838 proposed a protruding ridge solution but did not reveal how to better solve the problem of high overall flexural strength and small difference in local flexural strength of the product. In addition, because porcelain raw materials are used and a press of more than thousands of tons is used to press the body of the porcelain plate containing ridges in one step, it is necessary to solve the objective problem of easy demolding and no cracks after pressing, and to overcome the problem of no cracking, no dark cracks, and strength matching after the firing process of drainage, oxidation, exhaust, and shrinkage during firing. Only after these technical problems are solved, the one-piece molding production of porcelain plate products containing prefabricated protrusions with a height of not less than 8 mm and a flat plate body thickness of not less than 6 mm can become feasible.

[0021] The reason why the minimum edge height of 8mm and the flat layer thickness of 6mm are defined is designed in combination with practical applications. For edge heights less than 8mm, the strength is not high after the secondary processing of grooving on the edge side, and the size of the grooves is limited. For flat layers less than 6mm, their wind pressure resistance in dry hanging applications is weak, posing a safety hazard.

[0022] Preferably, the angle α between the side surface of the prefabricated protrusion and the vertical direction is ≥20°.

[0023] Preferably, the prefabricated protrusion includes at least two boss edges, the boss edges have a prism with a length of not less than 40 mm and a narrowest width of not less than 20 mm, and the minimum spacing B between the at least two boss edges and the nearest side of the ceramic plate is 15 mm to 100 mm.

[0024] By such an arrangement, the boss edge is limited to a prism with a length of at least not less than 40 mm, and the narrowest width of the boss edge is not less than 20 mm. The boss edge can be set as an integrally formed long edge or be set to include multiple short edges, so as to meet the dry hanging requirements and also make the density distribution of the boss edge in the overall product board surface more even.

[0025] Preferably, one side or both sides of the boss edge are provided with lateral inner grooves.

[0026] By such arrangement, it becomes feasible to form a porcelain plate required for firm and reliable dry hanging with matching hangers by grooving the edge sides of the corresponding prefabricated protrusions or punching holes on the edge bodies through secondary processing, because the lateral inner grooves are arranged on the edge sides of the bosses, which are specially designed to reduce the damage caused by directly grooving and punching holes in the main body of the flat plate. The remaining prefabricated protrusions are for better increasing the strength of the plate, and the intervals between the protrusions greatly reduce the amount of raw materials used and make the product lighter.

[0027] This comprehensive design innovation solves the problem that the prior art is unable to produce a ceramic plate with a prefabricated protrusion height of 8mm-20mm and a flat layer thickness of 6mm-15mm, and further achieves the technical effect of using such a plate for safer dry hanging after secondary processing, which is another aspect of the creativity and practicality of the present invention.

[0028] Preferably, the prefabricated protrusion further includes a prefabricated molding portion outside the boss edge.

[0029] Preferably, there are pressing grooves between the prefabricated protrusions (21), and a plurality of reinforcing ribs are arranged in the pressing grooves.

[0030] By such an arrangement, a number of reinforcing ribs are arranged in the pressing groove formed in the prefabricated molding part, so that the flexural strength of the overall plate surface of the pressed ceramic plate is effectively enhanced, reducing the possibility of crack defects in the prefabricated molding part of the ceramic plate due to insufficient local or local directional strength, thereby improving the yield rate and facilitating production, transportation and practical application.

[0031] Preferably, the length of the reinforcing rib is b, 5mm≤b≤the length of the pressing groove, the draft angle between the inclined surfaces at both ends of the reinforcing rib and the surface of the flat blank layer is β, 10°≤β≤80°, and the height from the top of the reinforcing rib to the root of the prefabricated protrusion is h, h ​

[0032] Preferably, the length of the reinforcing rib is b, 15mm≤b≤50mm, the draft angle between the inclined surfaces at both ends of the reinforcing rib and the surface of the flat blank layer is β, 30°≤β≤60°, and the height from the top of the reinforcing rib to the root of the prefabricated protrusion is h, h

[0033] By setting in this way, the length of the reinforcing rib and the draft angle are specifically set, which effectively strengthens the flexural strength of the ceramic plate and facilitates demoulding and production.

[0034] Preferably, the prefabricated forming portion is configured to include a plurality of raised points, which are truncated cone-shaped or prism-shaped, and the raised points are distributed in a grid or matrix on the flat layer of the porcelain plate; or the prefabricated forming portion is configured to include a plurality of raised edges, the vertical cross-section of the raised edges is triangular or trapezoidal, and the angles at which the sides intersect are connected with arcs, and the raised edges are selected to be distributed in strips, S-shaped, herringbone-shaped, annular, fan-shaped, or a combination of one or more of these shapes on the flat layer of the porcelain plate.

[0035] Through such an arrangement, the prefabricated forming portion can be a raised point or a raised edge, and the distribution of the raised point or the raised edge can be diversified, which is conducive to achieving product diversification; further, the flexural strength and wind resistance of the product in different directions can be more evenly distributed.

[0036] Preferably, the prefabricated protrusion is provided with a pressed shoulder at the ends of the four sides of the ceramic plate, the distance between the pressed shoulder and the side edge of the ceramic plate is L, 5mm≤L≤35mm, and the height difference between the top surface of the pressed shoulder and the top surface of the prefabricated protrusion is △H, 1.5mm≤△H≤8mm.

[0037] ​By such arrangement, in the test and actual production stage, taking the convex ridges with strip distribution and triangular cross section as an example, a pressing groove is formed between two adjacent convex ridges. After firing, cracks are easily generated on the surface of the porcelain plate away from the prefabricated convexities and between the two adjacent pressing grooves, and the cracks are close to the edge of the porcelain plate. The formation of this crack is due to the fact that when the porcelain plate is formed by integrally pressing the porcelain raw material, the flat blank layer below the pressing groove is denser, and the porcelain located at the prefabricated convexities and the flat blank layer below is denser. The density of the raw material is relatively low, resulting in a large uneven density difference. After firing, cracks appear in the flat layer below the prefabricated protrusion due to insufficient raw material density. Pressing shoulders are set at the ends of the prefabricated protrusion on both sides of the plate. During the pressing process, the pressing shoulders are pressed according to the pressing mold set on the pressing shoulders, so that the density difference between the flat layer below the pressing groove and the prefabricated protrusion in the pressed porcelain plate is reduced to be within the required range of firing, melting and shrinkage, thereby eliminating the defects caused by cracks.

[0038] Preferably, a recessed portion is provided at the top of the boss edge, and the depth of the recessed portion does not exceed H1 / 2.

[0039] Through such an arrangement, this design is equivalent to pressing down the middle of a single edge of the same volume to increase the powder density of the edge, which provides one of the effective means of adjusting the density of the boss edge. The top of the boss edge near the two sides is designed with a recessed shape with a depth not exceeding half the height of the edge, so that the top of the edge maintains the required height, and the overall powder is compacted more compactly so that the density of the edge body can be adjusted and controlled to be relatively consistent with others. This matching design of various parameters such as angle, edge height, design of recess on the edge, and spacing can effectively adjust the technical difficulties of demolding and uniform density, and realize the production of porcelain body products with a raised edge height of 8mm-20mm and a flat layer thickness of 6mm-15mm.

[0040] Preferably, the boss edge is formed by combining a prefabricated forming portion and a reinforcing rib.

[0041] Through such an arrangement, this design is that each protrusion is uniformly a prefabricated forming part, and by lengthening the reinforcing ribs at the predetermined position, it is easier to design the required long or short boss edges for the outer grooves for dry hanging, or a certain number of such boss edge shapes can be evenly arranged on the product board surface, so that the overall board surface of the product is more relatively uniform when subjected to force and the blank is formed.

[0042] Preferably, the spacing C between the two sides of the top of the prefabricated protrusion is not less than 3 mm, and the spacing A between the two sides of each boss edge at the H1 / 2 position is 15 mm to 70 mm.

[0043] Through such an arrangement, the prefabricated protrusions can ensure that the porcelain products have sufficient strength, and at the same time support the stable transmission of the plates in the roller kiln, avoiding the occurrence of quality defects caused by the tip breaking and falling off. In addition, the prefabricated protrusions are specifically widened to make them ribs that can be used for secondary processing to produce lateral inner grooves that can be buckled into the hangers. The widened design greatly ensures that the buckles used for dry hanging components are firm and the strength is guaranteed.

[0044] Preferably, when viewed from a vertical cross section of the porcelain plate, intersection points between two adjacent side edges of the prefabricated protrusions and the surface of the flat green sheet overlap or are no more than 10 mm apart.

[0045] Through such an arrangement, this design makes it easy for the reverse-designed pressing mold to effectively and fully expel and collect the fluid raw materials with a moisture content of less than 9% that are evenly distributed in the corresponding gap intervals during the pressing process, so that the density distribution of the raw materials in each edge and the flat layer is relatively uniform within the process range that can be demolded and can be fired and cooled without cracking. This is also achieved through hundreds of tests based on the fluidity of the porcelain powder, testing and adjusting the density of the powder, adjusting the height, angle or depth of the raised prism or reinforcing ribs and other parameters.

[0046] Preferably, the surface of the ceramic plate facing away from the prefabricated protrusions is flat or has a concave-convex texture with a depth of 0.5 mm to 5 mm.

[0047] By such an arrangement, the three-dimensional effect of the surface decoration is more rich.

[0048] Preferably, the surface of the ceramic plate facing away from the prefabricated protrusions is a ceramic blank surface or a decorative layer containing inkjet patterns, glazes, and dry granular materials.

[0049] Preferably, the top of the boss edge is provided with a conical recessed hole with a predetermined spacing.

[0050] By configuring in this way, the conical recessed hole can be used in conjunction with the dry hanging piece for buckle installation and further bolt reinforcement, thereby further improving the strength and firmness of the buckle connection and facilitating installation.

[0051] As a preferred material, the ceramic plate has a water absorption rate of less than 0.5% and a density between 1.75 and 1.95 g / cm 3 Lightweight porcelain body or density >2.3g / cm 3 Conventional porcelain body.

[0052] Based on the same inventive concept, the second object of the present invention is to provide a method for manufacturing a ceramic plate formed by one-time dry pressing of a prefabricated mold, which comprises the following steps:

[0053] Step 1: First, the bottom mold of the ceramic press is prepared according to the reverse design of the above-mentioned ceramic plate product, and the surface mold is designed and prepared according to the reverse of the flat or concave-convex shape, as the upper and lower molds required for pressing, and installed on the ceramic press of the production line;

[0054] Step 2: Prepare the porcelain raw materials for producing porcelain tile products;

[0055] Step 3: Evenly distribute the ceramic raw material of required thickness to the pressing and forming position of the ceramic press through the distribution grid;

[0056] Step 4: pressing and forming into a green body;

[0057] Step 5: Use conventional control to transport the green body into a drying kiln for drying and a firing kiln with a maximum temperature of 1150℃-1220℃ for firing into a semi-finished green body;

[0058] Step 6: cooling, cutting and grinding edges to obtain a semi-finished product of a ceramic plate product containing prefabricated protrusions;

[0059] Step 7: Using a predetermined processing tool to cut and grind one or both sides of the boss edge of the semi-finished ceramic plate product to form a lateral inner groove of a predetermined shape and depth.

[0060] Preferably, in step one, the ceramic press is a stamping type, roller pressing type or top pressing type dry pressing ceramic press.

[0061] Preferably, the ceramic raw material is a conventional powdery or granular ceramic raw material with a water content not higher than 9%.

[0062] Preferably, the bottom mold and the surface mold are reversely designed according to the corresponding bottom and surface shapes of the above-mentioned ceramic sheet products and combined with the pressing molding and shrinkage rate of ceramic tiles, that is, the ceramic sheet product and the bottom mold, the ceramic sheet product and the surface mold are corresponding male and female matching shapes.

[0063] Preferably, after the pressed body enters the drying step five, it first enters the glaze line process for inkjet printing of a predetermined pattern and surface treatment of applying glaze and dry granular materials to form a decorative layer, and then enters the firing kiln process for firing.

[0064] Preferably, after step seven, the boss edges are buckled with corresponding prefabricated profiles and bolt components to form an assembled product that can be used for firm dry hanging applications.

[0065] Compared with the prior art, the present invention has achieved beneficial technical effects:

[0066] 1. The invention proposes a ceramic plate formed by dry pressing in one step using a prefabricated mold. The back adopts a prefabricated convex design of 8-20 mm. The convex at the predetermined position is designed to be a boss edge with a length of at least 40 mm and a narrowest width of 20 mm through a reinforcing rib, or a boss edge with a length of at least 40 mm and a narrowest width of 20 mm is directly designed at the predetermined position, and then the two sides of the boss edge are grooved to form a lateral inner groove of a predetermined shape and size. The innovative design can make the metal profile buckle in the lateral inner groove of the processed boss edge according to the shape, or at the same time supplemented with a bolt reinforcement kit, so that the ceramic plate can be inserted through the hanger. The invention can realize the application of curtain wall dry hanging in a safer and more solid way, because the force direction of the dry hanging curtain wall is the vertical upward and downward force, so the force on the line and the surface after the groove sleeve is buckled is firm and reliable, and the set can be reinforced with bolt components so that the set as a whole can protect the prefabricated protrusion, which will be more solid; and because the plate of the invention adopts a porcelain body formed by dry pressing a flat blank layer and a prefabricated protrusion as a whole, it is pressed by a large-tonnage press and fired at a high temperature of up to 1150°C to 1200°C, and has the characteristics of high density, high strength and good integrity; thus, a curtain wall material with better physical and chemical properties and safer and more solid dry hanging is provided for the dry hanging application of building curtain walls.

[0067] 2. The present invention proposes a ceramic plate that is formed by one-time dry pressing of a prefabricated mold, and the prefabricated protrusions on the back thereof are designed to be spaced apart. Compared with a solid flat body without prefabricated protrusions but reaching the same thickness, the present invention greatly saves the weight of the body and materials compared with a flat body without sacrificing the effect and the strength fully reaching the national standard. For example, a flat layer body is 1 cm, a prefabricated protrusion is 1.3 cm, an angle of 33° between the side of the prefabricated protrusion and the vertical direction, and the intersection of the prefabricated protrusion and the bottom surface intersects, which can save about a quarter of the body weight. This will produce more beneficial effects of energy saving and load reduction. First, the load on the wall used for dry hanging is greatly reduced; second, the raw materials for making products are greatly saved; third, the energy consumption for firing when making products is greatly saved; and fourth, the transportation weight is greatly saved. Such load reduction and cost savings are obvious, which is more in line with the development direction of green, low carbon and environmental protection, so it itself has the comprehensive effect of integrated molding and light weight; fifthly, when the present invention adopts the ceramic blank made of lightweight formula raw materials, through these advantages of the present invention combined with the lightweight ceramic blank, the load will be further greatly reduced, and it will have more market application prospects.

[0068] 3. Several reinforcing ribs are arranged in the pressing groove of the prefabricated molding part, which overcomes the technical problems of specific local directionality and low strength, and can effectively improve the overall flexural strength of the finished ceramic plate produced, adding more protection for practicality and safety.

[0069] 4. Pressing shoulders are arranged at the ends of the convex edges on the four sides of the ceramic plate, which effectively reduces the defect of cracks formed on the sides of the finished ceramic plate and improves the yield of the product.

[0070] 5. The shapes of the prefabricated forming parts are diversified, which is conducive to improving the diversity of products. And through this design, the overall board surface can be more evenly resisted in terms of pressure, wind resistance and flexure, thus greatly reducing the problem of easy damage or cracking due to uneven local flexural strength.

[0071] 6. The ceramic plate formed by dry pressing in one time using a prefabricated mold proposed in the present invention belongs to the field of ceramic product production. The existing technology for the production of ceramic tiles is very mature, so the reproducibility of the present invention is very good. In addition, through the existing ceramic tile production technology, a ceramic inkjet machine is used to spray ceramic color ink on the surface of the product of the present invention to form a predetermined color pattern, and then glaze, dry particles and other materials are applied to perform surface decorative effect treatment. The surface can be obtained by collecting various materials such as natural stone, wood grain, cloth grain, watercolor, oil painting, etc., and scanning to form data information to form a pattern. The file is then printed on the surface of the product by a ceramic inkjet machine to form a rich and diverse effect of restoring the digital inkjet texture pattern. This will provide a sheet product with a safer dry-hanging design structure, more diverse surface effects, and higher physical and chemical properties for curtain wall dry-hanging applications. This kind of ceramic tile process, which can be processed by a ceramic inkjet machine to form a variety of color patterns and is industrially produced, meets people's improved aesthetic needs and improved safety performance requirements. This is incomparable to the monotonous colors of extrusion processes such as clay or high-moisture clay, and is not something that can be achieved by extrusion processes.

[0072] 7. The present invention proposes a ceramic plate formed by one-time dry pressing of a prefabricated mold. Because the production process of porcelain tiles is adopted, a colored body effect can be produced through mixing means, and a colored inkjet pattern effect can be produced on the surface, as well as decoration after the application of glazes and dry particles of various fire degrees, forming a rich body and surface decoration effect. This not only provides a better plate for curtain wall dry hanging, but can also be used for shorter wall and floor paving applications. The design of this prefabricated protrusion also greatly increases the bite force between the adhesive material and the edge of the plate, so the paving application is more firm.

[0073] 8. The present invention proposes a ceramic plate formed by one-time dry pressing of a prefabricated mold, which can first be dry-hung on the ground with standardized sleeves, bolts, screws and other components, and then assembled and installed in a standardized manner, thereby achieving fast and efficient assembly and application.

[0074] 9. The present invention proposes a production process for a ceramic plate product formed by one-time dry pressing using a prefabricated mold. Through innovative design and preparation of the mold, matching control of the raw material formula, matching of the press, and design of a suitable drying and kiln firing system, large-scale industrial production can be achieved in the production line process of ceramic tiles, which greatly improves the efficiency compared to the extrusion process.

[0075] 10. The present invention proposes a production process for ceramic plate products that can be formed by dry pressing in one time using a prefabricated mold. Through the innovative design and preparation of the mold, it is achieved that a flat cloth can be pressed to produce a product with a predetermined designed raised edge. It is well known in the industry that flat cloth is the most efficient and simple cloth method in the production process of ceramic tiles. The innovative design of the present invention satisfies the innovative realization of this method of forming a predetermined shape by laying the cloth in one time, which not only produces a predetermined innovative design effect, but also reduces the difficulty of controlling the production technology and improves the efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0076] Figure 1 A three-dimensional design diagram of a pressed body of a ceramic plate formed by one-time dry pressing of a prefabricated mold and a matching mold in one embodiment of the present invention;

[0077] Figure 2 It is a schematic cross-sectional view of a pressed body of a ceramic plate formed by one-time dry pressing of a prefabricated mold and a matching mold in one embodiment of the present invention.

[0078] Figure 3 for Figure 2 Enlarged schematic diagram of the middle J part.

[0079] Figure 4 It is a three-dimensional diagram of a ceramic plate formed by one-time dry pressing of a prefabricated mold in the second embodiment of the present invention;

[0080] Figure 5 for Figure 4 Enlarged view of the middle M part;

[0081] Figure 6 It is a partial schematic diagram of a top view of a ceramic plate formed by one-time dry pressing of a prefabricated mold in the second embodiment of the present invention;

[0082] Figure 7 for Figure 6 Partial schematic diagram of the FF section;

[0083] Figure 8 for Figure 6 A partial schematic diagram of the middle G direction;

[0084] Fig. 9 It is a schematic diagram of the state of a porcelain plate and a blank bottom mold formed by one-time dry pressing of a prefabricated mold without a pressing shoulder;

[0085] Fig.10 A schematic diagram of the state of the porcelain plate and the blank bottom mold during pressing, which is formed by one-time dry pressing, with a prefabricated mold for pressing the shoulder;

[0086] Fig.11 This is a schematic diagram of an inkjet texture on the surface of a ceramic plate formed by one-time dry pressing of a prefabricated mold in one embodiment of the present invention.

[0087] Fig.12 It is a schematic cross-sectional view of a ceramic plate formed by dry pressing of a prefabricated mold in one embodiment of the present invention after secondary processing of predetermined prefabricated protrusions;

[0088] Fig.13 for Fig.12 Enlarged view of the middle K section;

[0089] Fig.14 It is a three-dimensional diagram of a ceramic plate formed by one-time dry pressing of the prefabricated mold in the third embodiment of the present invention;

[0090] Fig.15 It is a three-dimensional diagram of a ceramic plate formed by one-time dry pressing of a prefabricated mold in the fourth embodiment of the present invention;

[0091] Fig.16 It is a three-dimensional diagram of a ceramic plate formed by one-time dry pressing of the prefabricated mold in the fifth embodiment of the present invention;

[0092] Fig.17 It is a three-dimensional diagram of a ceramic plate formed by one-time dry pressing of the prefabricated mold in the sixth embodiment of the present invention;

[0093] Fig.18 It is a three-dimensional diagram of a ceramic plate formed by one-time dry pressing of a prefabricated mold in Embodiment 7 of the present invention;

[0094] Fig.19 It is a three-dimensional diagram of a ceramic plate formed by one-time dry pressing of the prefabricated mold in the eighth embodiment of the present invention;

[0095] Fig. 20 It is a three-dimensional diagram of a ceramic plate formed by one-time dry pressing of the prefabricated mold in the ninth embodiment of the present invention;

[0096] Fig.21 It is a three-dimensional diagram of a ceramic plate formed by one-time dry pressing of the prefabricated mold in the tenth embodiment of the present invention;

[0097] Fig. 22 It is a three-dimensional diagram of a ceramic plate formed by one-time dry pressing of a prefabricated mold in Example 11 of the present invention;

[0098] Fig.23 It is a schematic diagram of the principle of the method for manufacturing a ceramic plate formed by one-time dry pressing of a prefabricated mold in the twelfth embodiment of the present invention.

[0099] The technical features indicated by the reference numerals are as follows:

[0100] 11. Ceramic plate; 12. Blank bottom mold; 121. Raised portion; 122. Grooved portion; 123. Pressed protrusion; 21. Prefabricated protrusion; 211. Pressed shoulder; 22. Flat blank layer; 221. Dense area; 222. Loose area; 23. Pressed groove; 231. Reinforcement rib; 31. Prefabricated forming portion; 311. Raised edge; 312. Raised point; 41. Boss edge; 410. Prism; 411. Lateral inner groove; 412. Concave portion; 413. Concave hole; 5. Ceramic press; 6. Blank surface mold; 7. Raw material conveying device; 701. Lower hopper; 702. Collecting hopper; 9. Conveying roller table. DETAILED DESCRIPTION

[0101] In order to make the purpose, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with embodiments, but the scope of protection claimed in the present invention is not limited to the following specific embodiments.

[0102] Embodiment 1

[0103] refer to Figure 1 , Figure 2 , Figure 3 , Fig.12 as well as Fig.13 This embodiment discloses a ceramic plate 11 formed by one-time dry pressing of a prefabricated mold, comprising a flat layer 22 and a prefabricated protrusion 21, wherein the flat layer 22 and the prefabricated protrusion 21 are integrally formed by dry pressing of a ceramic raw material, wherein the height H1 of the prefabricated protrusion 21 is 8 mm to 20 mm, and the thickness H2 of the flat layer 22 is 6 mm to 15 mm;

[0104] From the cross section of the porcelain plate 11, the angle α between the side of the prefabricated protrusion 21 and the vertical direction is ≥15°, and any edge of the prefabricated protrusion 21 does not overlap in the vertical projection of the flat layer 22. The prefabricated protrusion 21 includes at least two boss edges 41. In this embodiment, the boss edge 41 is in the shape of an elongated strip, the boss edges 41 are parallel to each other, and the boss edge 41 is parallel to any two parallel edges of the porcelain plate 11. The minimum parallel spacing B between the boss edge 41 and the nearest side edge of the porcelain plate 11 is 15mm to 100mm. A lateral inner groove 411 is provided on one side or both sides of the boss edge 41. The lateral inner groove 411 is formed by secondary processing. Whether the lateral inner groove 411 is provided on both sides of the boss edge 41 is selected according to actual needs.

[0105] The height H1 of the prefabricated protrusion 21 is 8mm to 15mm. Preferably, H1 can be selected from 8.5mm, 9mm, 9.5mm, 10mm, 10.5mm, 11mm, 11.5mm, 12mm, 12.5mm, 13mm, 13.5mm, 14mm or 14.5mm. The thickness H2 of the flat layer 22 is 8mm to 13mm. Preferably, H2 can be selected from 6.5mm, 7mm, 8mm, 8.5mm, 9mm, 9.5mm, 10mm, 10.5mm, 11mm, 11.5mm, 12mm, 12.5mm.

[0106] Preferably, the angle α between the side surface of the prefabricated protrusion 21 and the vertical direction is ≥20°.

[0107] Preferably, a recessed portion 412 is provided at the top of the boss ridge 41 , and the depth of the recessed portion 412 does not exceed H1 / 2.

[0108] Preferably, reference Figure 2 The distance A between the two sides of each boss edge 41 at the H1 / 2 position is 15 mm to 70 mm.

[0109] refer to Figure 1 The prefabricated protrusion 21 also includes a prefabricated molding portion 31 arranged in the middle of the ceramic plate. In this embodiment, the prefabricated molding portion 31 is configured to include a plurality of protruding edges 311, and the vertical cross-section of the protruding edges 311 is a triangle. In other embodiments, the vertical cross-section shape of the protruding edges 311 can also be a trapezoid, and the corners of the protruding edges are transitioned through arcs, that is, they are connected with arcs.

[0110] The raised edges 311 are distributed on the surface of the porcelain plate in one or more distribution forms selected from strip-shaped, S-shaped, herringbone-shaped, annular, fan-shaped, and fan-shaped combinations. In this embodiment, the raised edges are distributed on the surface of the porcelain plate in strip-shaped, and the raised edges are arranged parallel to the boss edges.

[0111] Preferably, reference Figure 2 and Figure 3 The spacing C between the two sides of the top of the prefabricated protrusion 21 is not less than 3 mm, and the top of the prefabricated protrusion 21 is transitioned through an arc.

[0112] Preferably, from the cross section of the ceramic plate 11, the intersection points of two adjacent sides of the prefabricated protrusions 21 and the flat layer 22 coincide with each other or are no more than 10 mm apart (e.g. Figure 3 Parameter D in ).

[0113] Preferably, the distance between the intersections of two adjacent sides of the prefabricated protrusions 21 and the flat blank layer 22 is no more than 5 mm.

[0114] Preferably, the surface of the ceramic plate 11 away from the prefabricated protrusions 21 is flat or has a concave-convex texture with a depth of 0.5 mm to 5 mm (not shown in the figure).

[0115] Preferably, if Fig.11 As shown, the surface of the ceramic plate 11 facing away from the prefabricated protrusions 21 is a ceramic blank surface or a decorative layer containing inkjet patterns, glaze, and dry granular materials.

[0116] Preferably, the ceramic plate 11 is a conventional ceramic body or a ceramic body with a water absorption rate of less than 0.5% and a density between 1.75 and 1.9 g / cm 3 Lightweight porcelain body or density >2.3g / cm 3 Conventional porcelain body.

[0117] Embodiment 2

[0118] Based on the first embodiment, this embodiment discloses another ceramic plate formed by one-time dry pressing of a prefabricated mold, which is different from the first embodiment in that:

[0119] refer to Figure 4 and Figure 5 A plurality of pressing grooves 23 are formed between the prefabricated protrusions. In the present embodiment, the pressing groove 23 is formed between two adjacent protruding edges 311. A plurality of reinforcing ribs 231 are arranged in the pressing groove 23. The reinforcing ribs 231 may be evenly spaced along the extension direction of the length of the pressing groove 23.

[0120] In other embodiments, the reinforcing rib 231 is integrated with the raised edge 311 of the prefabricated molding portion to form a boss edge.

[0121] refer to Figure 6 and Figure 7 The length of the reinforcing rib 231 is b, 5mm≤b≤the length of the pressing groove 23, preferably, 15mm≤b≤50mm, and considering the spacing and height setting of two adjacent prefabricated protrusions 21, b can be selected as 20mm;

[0122] The draft angle of the upper part of the reinforcing rib 231 is β, 10°≤β≤80°, preferably in the range of 30°≤β≤60°, more preferably, β is 40°;

[0123] The height from the top of the reinforcing rib 231 to the root of the prefabricated protrusion 21 (ie, to the surface of the flat layer 22 facing the prefabricated protrusion 21) is h, h

[0124] refer to Figure 4 ​The reinforcing ribs 231 are only formed in the pressed grooves 23 between the boss edges 41 and no reinforcing ribs 231 are provided between the boss edges 41 and other adjacent prefabricated protrusions 21. In other embodiments, reinforcing ribs 231 may be provided in all the pressed grooves 23 according to strength requirements.

[0125] refer to Figure 4 as well as Figure 5 The ceramic plate is provided with a pressing shoulder 211 at both ends of the boss edge 41 along its length direction. The pressing shoulder 211 is formed on all the prefabricated protrusions 21 arranged along the side of the ceramic plate. The height of the plane of the pressing shoulder 211 is lower than the height of the prefabricated protrusion 21.

[0126] refer to Figure 5 , Figure 6 as well as Figure 8 The distance from the pressed shoulder 211 to the nearest side of the ceramic plate is L, and L is set to: 5mm≤L≤35mm, preferably, L is selected to be 20mm

[0127] The height difference between the top surface of the pressed shoulder 211 and the top surface of the prefabricated protrusion 21 is △H, and △H is set to: 1.5mm≤△H≤8mm. Preferably, △H can be selected from 2mm, 2.5mm, 3mm, 3.5mm, 4mm, 4.5mm, 5mm, 5.5mm, 6mm, 6.5mm, 7mm, and 7.5mm.

[0128] refer to Fig. 9 Before the pressing shoulder 211 is provided, the blank bottom mold 12 provided in the reverse direction of the product includes a raised portion 121 and a recessed portion 122; the recessed portion 122 is provided between two adjacent raised portions 121, the raised portion 121 is used to press and form a pressing groove 23, and the recessed portion 122 forms a prefabricated protrusion 21. During the pressing process, the raised portion 121 and the recessed portion 122 of the blank mold press down the ceramic raw material synchronously, and the flat blank layer 22 located below the pressing groove 23 is subjected to a relatively high pressure from the raised portion 121. The ceramic raw materials are squeezed and arranged closely, thereby forming a dense area 221 at this position, while the compressive strength of the flat green layer 22 located at the prefabricated protrusion 21 and below is relatively small, and the ceramic raw materials are arranged loosely, forming a loose area 222. This is particularly obvious on the surface of the two ends of the ceramic plate near the extension direction of the prefabricated protrusion 21. During the firing process, the ceramic raw materials in the loose area 222 are not saturated enough, resulting in crack defects in the loose area 222 on the surface of the flat green layer 22 in the ceramic plate away from the prefabricated protrusion 21;

[0129] refer to Fig.10, and after the pressing shoulder 211 is set, the blank bottom mold 12 needs to make an adaptive adjustment design. Referring to the figure, the blank bottom mold 12 includes a protruding portion 121, a groove portion 122, and a pressing protrusion 123. The pressing protrusion 123 is arranged in the groove portion 122 and is located at both ends of the groove portion 122 along the length extension direction thereof. The pressing protrusion 123 is used to form a pressing shoulder 211 at both ends of the prefabricated protrusion 21; the setting of the pressing protrusion 123 can make the pressing protrusion 123 and the protruding portion 121 uniformly press down the porcelain raw materials of the flat blank layer 22 located at the prefabricated protrusion 21 and below and the flat blank layer 22 located below the pressing groove 23 during the pressing process, so that the porcelain raw materials of the flat blank layer 22 are evenly distributed and the density is kept consistent, thereby effectively reducing the formation of crack defects on the surface of the flat blank layer 22 of the finished porcelain plate after firing.

[0130] Embodiment 3

[0131] refer to Fig.14 Based on the above embodiment, this embodiment discloses another ceramic plate formed by one-time dry pressing of a prefabricated mold, which is different from the above embodiment in that:

[0132] The top of the boss rib 41 is provided with a conical recessed hole 413 with a predetermined interval.

[0133] Embodiment 4

[0134] refer to Fig.15 Based on the above embodiment, this embodiment discloses another ceramic plate formed by one-time dry pressing of a prefabricated mold, which is different from the above embodiment in that:

[0135] The vertical cross section of the raised ridge 311 is trapezoidal, and the raised ridge 311 is distributed in an S shape. The extending direction of the raised ridge 311 is the same as the extending direction of the boss ridge 41 .

[0136] Embodiment 5

[0137] refer to Fig.16 Based on the above embodiment, this embodiment discloses another ceramic plate formed by one-time dry pressing of a prefabricated mold, which is different from the above embodiment in that:

[0138] The vertical cross section of the raised edge 311 is a trapezoid, and the raised edges 311 are distributed in a herringbone shape, and the distribution state of the herringbone shape is distributed with the midline of one side of the porcelain plate as the symmetry axis.

[0139] Embodiment 6

[0140] refer to Fig.17 Based on the above embodiment, this embodiment discloses another ceramic plate formed by one-time dry pressing of a prefabricated mold, which is different from the above embodiment in that:

[0141] The vertical cross section of the raised edge 311 is a trapezoid, and the raised edge 311 is distributed in a ring shape. The distribution state of the ring shape is that the center of the porcelain plate is the center of the circle and the raised edge 311 is distributed from the inside to the outside.

[0142] Embodiment 7

[0143] refer to Fig.18 Based on the above embodiment, this embodiment discloses another ceramic plate formed by one-time dry pressing of a prefabricated mold, which is different from the above embodiment in that:

[0144] The vertical cross section of the raised edge 311 is a trapezoid. The raised edge 311 is fan-shaped or a combination of fan-shaped distributions. The fan-shaped and fan-shaped distributions are regular distributions or irregular distributions.

[0145] Embodiment 8

[0146] refer to Fig.19 Based on the above embodiment, this embodiment discloses another ceramic plate formed by one-time dry pressing of a prefabricated mold, which is different from the above embodiment in that:

[0147] The prefabricated molding part 31 is configured to include a plurality of protrusions 312, which are truncated cone-shaped or prism-shaped. The protrusions 312 are distributed in a grid or matrix on the flat layer of the porcelain plate. In this embodiment, the protrusions 312 are truncated cone-shaped and distributed in a matrix.

[0148] Embodiment 9

[0149] refer to Fig. 20 Based on the above embodiment, this embodiment discloses another ceramic plate formed by one-time dry pressing of a prefabricated mold, which is different from the above embodiment in that:

[0150] The protruding points 312 are prism-shaped and distributed in a mesh pattern, and the mesh pattern is cross-shaped at 45 degrees.

[0151] Embodiment 10

[0152] refer to Fig.21 This embodiment discloses another method for manufacturing a ceramic plate product formed by dry pressing a prefabricated mold. Based on the above embodiment, the difference between this embodiment and the above embodiment is that:

[0153] refer to Fig.21 The boss rib 41 may be composed of a plurality of independent prisms 410, and the length of the prism 410 is not less than 40 mm and the minimum width is not less than 20 mm.

[0154] refer to Fig.21 The prisms arranged along the same side of the ceramic plate product have the same orientation.

[0155] Embodiment 11

[0156] refer to Fig. 22 This embodiment discloses another method for manufacturing a ceramic plate product formed by dry pressing a prefabricated mold. Based on the above embodiment, the difference between this embodiment and the above embodiment is that:

[0157] The prisms arranged along the same side of the ceramic sheet product have different orientations.

[0158] Embodiment 12

[0159] refer to Fig.23 This embodiment discloses a method for manufacturing a ceramic plate product formed by dry pressing using a prefabricated mold, which is used to manufacture a ceramic plate product formed by dry pressing using a prefabricated mold in the above embodiment, and includes the following steps:

[0160] Step 1: Design the shape of the product. According to the plasticity of the raw material formula, the physical drainage of drying, the structural drainage, the design and matching of the drying and firing system of oxidation exhaust and sintering, the pressing and shrinkage rate of the porcelain tile, the various parameters of the pressed body are designed, and then the bottom mold 12 of the ceramic press 5 is reversely designed, such as Figure 1 , Figure 2 As shown; set the height H1 of the raised edge of the pressed green body to 13mm, the thickness of the flat layer of the pressed green body is 11mm, and the angle α between the side edge of the raised edge and the vertical direction is 32°, such as Figure 3 As shown;

[0161] Design and prepare a blank surface mold 6 with a flat surface or a concave-convex texture with a depth of 0.5mm-5mm;

[0162] Install the blank bottom mold 12 and the blank surface mold 6 on the ceramic press 5 of the production line;

[0163] Step 2: Prepare conventional porcelain raw materials for producing porcelain tile products;

[0164] Step 3: Start the production equipment, the lower hopper 701 on the raw material conveying device 7 drops the loaded raw materials onto the collecting hopper 702, and the collecting hopper 702 includes a distribution grid (not shown in the figure), and the raw materials are evenly filled into the mold cavity of the ceramic press 5 through the distribution grid;

[0165] Step 4: Use the ceramic press mold described in step 1 to press and shape the green body and send it to the next process through the conveying roller table 9, such as Fig.23 As shown;

[0166] Step 5: Adjust the direction so that the straight raised edges of the green body are vertically placed into the drying kiln for drying and the firing kiln with the highest temperature reaching 1150℃-1220℃ for firing to become a semi-finished green body;

[0167] Step 6: cooling, cutting and grinding the edges to obtain a prefabricated mold dry-pressed ceramic plate product of the present invention;

[0168] Step 7: On one or both sides of the convex edge of the finally obtained prefabricated mold dry-pressed porcelain sheet product, according to the matching of the dry hanging profile, a predetermined processing tool is used for secondary processing and grinding to form an inner groove of a predetermined shape and depth, that is, a prefabricated mold dry-pressed porcelain sheet product is obtained, and the predetermined convex edge on the back side is a product with an inner groove that can firmly buckle the hanger, such as Fig.12 , Fig.13 As shown, the predetermined boss ridge 41 is processed to form a lateral inner groove, so that the boss ridge 41 is in a dovetail groove shape.

[0169] In order to better increase the strength of the edge, in actual implementation, under the conditions of edge height of 8mm-20mm and flat blank layer thickness of 8mm-15mm, the ratio of edge height to flat blank layer thickness is 1:1 to 1.5:1.

[0170] Preferably, in step 1, the ceramic press can be a stamping type, a roller pressing type or a top pressing type dry pressing ceramic press.

[0171] Preferably, in step 2, the ceramic raw material is a conventional powdery or granular ceramic raw material having a water content of less than 9%.

[0172] The shapes of the blank bottom mold 12 and the blank surface mold 6 are reversely designed according to the corresponding blank bottom and blank surface shapes of the ceramic plate product and combined with the pressing molding and shrinkage rate of the ceramic tile, that is, the ceramic plate product and the blank surface mold 6, the ceramic plate product and the blank bottom mold 12 are all male and female matching shapes.

[0173] Embodiment 13

[0174] Based on Example 12, in step 5, after drying in the drying kiln and before firing in the firing kiln, the glaze line process is entered to perform a surface decoration layer treatment of a predetermined pattern of inkjet and glaze dry particle process, and finally a prefabricated mold dry-pressed porcelain sheet product with an inkjet texture on the surface of the present invention is obtained, such as Fig.11 shown.

[0175] Embodiment 14

[0176] Based on the above embodiment, after step seven, the boss edge is buckled with corresponding prefabricated profiles and bolt components to form an assembled product that can be used for dry hanging applications firmly.

[0177] According to the disclosure and teaching of the above description, those skilled in the art to which the present invention belongs may also make changes and modifications to the above embodiments. Therefore, the present invention is not limited to the specific embodiments disclosed and described above, and some modifications and changes to the invention should also fall within the scope of protection of the claims of the present invention. In addition, although some specific terms are used in this specification, these terms are only for the convenience of description and do not constitute any limitation to the invention.

Claims

1. A ceramic plate formed by dry pressing in one step using a prefabricated mold, comprising a flat layer (22) and a plurality of prefabricated protrusions (21) arranged in advance, characterized in that: The flat layer (22) and the prefabricated protrusion (21) are integrally formed by dry pressing of a porcelain raw material, the height H1 of the prefabricated protrusion (21) is 8 mm to 20 mm, and the thickness H2 of the flat layer (22) is 6 mm to 15 mm; From the cross section of the ceramic plate (11), the angle α between the side of the prefabricated protrusion (21) and the vertical direction is ≥15°, and the vertical projection of any edge of the prefabricated protrusion (21) on the surface plane of the flat blank layer (22) does not overlap; The prefabricated protrusion (21) comprises at least two boss edges (41), the boss edges (41) have at least a prism (410) with a length of not less than 40 mm and a narrowest width of not less than 20 mm, and the minimum spacing B between the at least two boss edges (41) and the side edges closest to the ceramic plate (11) is 15 mm to 100 mm; The prefabricated protrusion (21) further comprises a prefabricated forming portion (31) outside the boss ridge (41); between the prefabricated protrusions (21) is a pressing groove (23); a plurality of reinforcing ribs (231) are arranged in the pressing groove (23); and the boss ridge (41) is formed by combining the prefabricated forming portion (31) and the reinforcing ribs (231).

2. The ceramic plate formed by one-step dry pressing of a prefabricated mold according to claim 1, characterized in that: The angle α between the side surface of the prefabricated protrusion (21) and the vertical direction is ≥20°.

3. The ceramic plate formed by one-step dry pressing of a prefabricated mold according to claim 1, characterized in that: One side or both sides of the boss edge (41) are provided with a lateral inner groove (411).

4. The ceramic plate formed by one-step dry pressing of a prefabricated mold according to claim 1, characterized in that: The length of the reinforcing rib (231) is b, 5mm≤b≤the length of the pressing groove (23); the draft angle between the inclined surfaces at both ends of the reinforcing rib (231) and the surface of the flat blank layer (22) is β, 10°≤β≤80°; the height from the top of the reinforcing rib (231) to the root of the prefabricated protrusion (21) is h, h<H1.

5. The ceramic plate formed by one-step dry pressing of a prefabricated mold according to claim 1, characterized in that: The length of the reinforcing rib (231) is b, 15mm≤b≤50mm, the draft angle between the inclined surfaces at both ends of the reinforcing rib (231) and the surface of the flat blank layer (22) is β, 30°≤β≤60°, and the height from the top of the reinforcing rib (231) to the root of the prefabricated protrusion (21) is h, h<H1.

6. The ceramic plate formed by one-step dry pressing of a prefabricated mold according to claim 1, characterized in that: The prefabricated molding part (31) is configured to include a plurality of raised points (312), wherein the raised points (312) are truncated cone-shaped or prism-shaped, and the raised points (312) are distributed in a mesh or matrix on the flat layer of the porcelain plate (11); or the prefabricated molding part (31) is configured to include a plurality of raised edges (311), wherein the vertical cross-section of the raised edges (311) is triangular or trapezoidal, and the angles at which the sides intersect are connected with an arc, and the raised edges (311) are distributed on the flat layer of the porcelain plate (11) in a strip shape, an S shape, a herringbone shape, a ring shape, a fan shape, or a combination of one or more of these shapes.

7. The ceramic plate formed by one-step dry pressing of a prefabricated mold according to any one of claims 1 to 6, characterized in that: The prefabricated protrusion (21) is provided with pressed shoulders (211) at the ends of the four sides of the ceramic plate (11), the distance between the pressed shoulders (211) and the side of the ceramic plate (11) is L, 5mm≤L≤35mm, and the height difference between the top surface of the pressed shoulders (211) and the top surface of the prefabricated protrusion (21) is △H, 1.5mm≤△H≤8mm.

8. The ceramic plate formed by one-step dry pressing of a prefabricated mold according to claim 1, characterized in that: A recessed portion (412) is provided at the top of the boss ridge (41), and the depth of the recessed portion (412) does not exceed H1 / 2.

9. The ceramic plate formed by one-step dry pressing of a prefabricated mold according to claim 1 or 3, characterized in that: The spacing C between the two sides of the top of the prefabricated protrusion (21) is not less than 3 mm, and the spacing A between the two sides of each boss edge (41) at the H1 / 2 position is 15 mm to 70 mm.

10. The ceramic plate formed by one-step dry pressing of a prefabricated mold according to any one of claims 1 to 6, characterized in that: Viewed from a vertical cross section of the porcelain plate (11), the intersection points of the side edges of two adjacent prefabricated protrusions (21) and the surface of the flat blank layer (22) coincide with each other or are no more than 10 mm apart.

11. The ceramic plate formed by one-step dry pressing of a prefabricated mold according to any one of claims 1 to 6, characterized in that: The surface of the porcelain plate (11) facing away from the prefabricated protrusion (21) is a plane or has a concave-convex texture with a depth of 0.5 mm to 5 mm.

12. The ceramic plate formed by one-step dry pressing of a prefabricated mold according to any one of claims 1 to 6, characterized in that: The surface of the porcelain plate (11) facing away from the prefabricated protrusion (21) is a porcelain blank surface or a decorative layer containing inkjet patterns, glaze materials, and dry granular materials.

13. The ceramic plate formed by one-step dry pressing of a prefabricated mold according to claim 1 or 3, characterized in that: The top of the boss ridge (41) is provided with a conical recessed hole (413) with a predetermined spacing.

14. The ceramic plate formed by one-step dry pressing of a prefabricated mold according to any one of claims 1 to 6, characterized in that: The ceramic plate (11) has a water absorption rate of less than 0.5% and a density between 1.75 and 1.95 g / cm 3 Lightweight porcelain body or density >2.3g / cm 3 Conventional porcelain body.

15. A method for manufacturing a ceramic plate formed by dry pressing in a prefabricated mold, characterized in that: It includes the following steps: Step 1: First, the bottom mold (12) of the ceramic press (5) is prepared by reverse design of the ceramic plate (11) product according to any one of claims 1 to 14, and the surface mold (6) is designed and prepared in the reverse direction of the flat or concave-convex shape, as the upper and lower molds required for pressing, and installed on the ceramic press (5) of the production line; Step 2: Prepare the porcelain raw materials for producing porcelain tile products; Step 3: evenly distribute the ceramic raw material of required thickness to the pressing and forming position of the ceramic press (5) through the distribution grid; Step 4: pressing and forming into a green body; Step 5: Use conventional control to transport the green body into a drying kiln for drying and a firing kiln with a maximum temperature of 1150℃-1220℃ for firing into a semi-finished green body; Step 6: cooling, cutting and grinding the edges to obtain a semi-finished product of a ceramic plate product containing prefabricated protrusions (21); Step 7: Using a predetermined machining tool to cut and grind one or both sides of the boss edge (41) of the semi-finished ceramic plate (11) product to form a lateral inner groove (411) of a predetermined shape and depth.

16. The manufacturing method according to claim 15, characterized in that: In step 1, the ceramic press (5) is a stamping type, roller pressing type or top pressing type dry pressing forming ceramic press.

17. The manufacturing method according to claim 15, characterized in that: The ceramic raw material is a conventional powdery or granular ceramic raw material with a water content not higher than 9%.

18. The manufacturing method according to claim 15, characterized in that: The shapes of the blank bottom mold (12) and the blank surface mold (6) are reversely designed according to the corresponding blank bottom and blank surface shapes of the ceramic plate (11) product and in combination with the pressing and shrinkage rate of the ceramic tile, that is, the ceramic plate (11) product and the blank bottom mold (12), and the ceramic plate (11) product and the blank surface mold (6) are corresponding male and female matching shapes.

19. The manufacturing method according to claim 15, characterized in that: After the pressed body enters the drying step in step five, it first enters the glaze line process for inkjet printing of a predetermined pattern and surface treatment of applying glaze and dry granular materials to form a decorative layer, and then enters the firing kiln process for firing.

20. The manufacturing method according to claim 15, characterized in that: After step seven, the boss edge (41) is buckled with corresponding prefabricated profiles and bolt components to form an assembled product that can be used for dry hanging applications.

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