Ceramic plate convenient for dry hanging, manufacturing method and mold thereof

Abstract

The present invention relates to the field of ceramic technology, and discloses a ceramic plate that is convenient for dry hanging, as well as a manufacturing method and mold thereof. The back of the ceramic plate has a concave-convex shape, and at least two raised surface areas are provided along the outer periphery of the back of the ceramic plate. Before being fired and formed, the ceramic plate is a green body made by integral dry pressing of ceramic powder. When viewed from a cross section of the green body of the ceramic plate, the inner side edges of the raised surface areas are inclined relative to the central vertical axis of the green body, and the predetermined angle a formed with the central vertical axis is set to 0°<a≤15°. After the green body of the ceramic plate is demolded by expansion during press forming, when viewed from the side of the mating surface of the back of the green body and the press mold, the point P' where the inner side vertex P of the raised surface area of ​​the green body is projected onto the back of the green body is outside the mold vertex Q. The ceramic plate of the present invention can be used for dry hanging of curtain walls, and the ceramic plate of the present invention can ensure that the concave-convex surface of the upper surface of the lower mold and the concave-convex surface of the green body are in a state that is easy to demold during the pressing process.

Description

Technical Field

[0001] The present invention relates to the technical field of building ceramics, in particular to a ceramic plate convenient for dry hanging, a manufacturing method thereof and a mould. Background Art

[0002] Ceramic panels have gradually been used in various types of building curtain walls due to their high flexural strength, controllable color difference, good freeze-thaw resistance, good stain resistance, good stability and low subsequent maintenance costs.

[0003] In the existing technology, dry hanging construction generally involves grooving and drilling holes on the back of a conventional integral slab to fix the back bolts. This method requires cutting and grinding the slab body, which will cause a certain degree of damage to the slab body. Therefore, sufficient thickness is required to ensure both safety and feasibility. However, since thicker slabs will bring heavier loads to the wall, it will bring safety hazards and problems such as high consumables and high energy consumption during the preparation process. Therefore, the pursuit of thin and light tiles with the ability to dry hang has always been a contradictory pursuit in the industry.

[0004] There is also a method of fixing the back bolts by grooving and punching holes at the position of the trapezoidal protrusions on the back of the pre-formed one-piece plate. This method causes relatively little damage to the plate itself and also saves raw materials. It is also lighter than the load of thick plates under the same area, and is the preferred choice for curtain wall dry hanging applications at this stage.

[0005] However, the existing technology has not yet developed a good ceramic tile product suitable for dry hanging, especially for large-sized ceramic tiles suitable for the exterior walls of buildings, such as tiles with a size of 1m×1m or more. Dry hanging requires ensuring that they are firmly fixed and do not fall off. However, there are few large ceramic tile products that can be directly manufactured and suitable for dry hanging in the existing ceramic tiles and manufacturing processes.

[0006] Based on the above, in order to reduce the load and reduce the damage to the panel body caused by secondary processing, especially the application of ceramic panels with firm hanging supports in curtain wall dry hanging, it is the research and development direction of industry insiders.

[0007] It can be seen that the existing technology still needs to be improved and enhanced. Summary of the Invention

[0008] In view of the above-mentioned deficiencies in the prior art, the purpose of the present invention is to provide a ceramic panel that is easy to dry-hang, a manufacturing method and a mold thereof, aiming to solve the problem that the ceramic panels need to be processed secondary and the dry-hanging of the ceramic panels is not secure in existing curtain wall dry-hanging applications.

[0009] In order to achieve the above object, the present invention adopts the following technical solutions:

[0010] A ceramic plate convenient for dry hanging, wherein the back of the ceramic plate has a concave-convex shape, and at least two raised surface areas are provided along the periphery of the back of the ceramic plate; before being fired and formed, the ceramic plate is a green body made of ceramic powder through integrated dry pressing; when viewed from a cross section of the green body of the ceramic plate, the inner side edges of the raised surface areas are inclined relative to the central vertical axis of the green body, and the predetermined angle a formed with the central vertical axis is set to 0°<a≤15°; the distance between the inner side vertex of the raised surface area of ​​the green body of the ceramic plate and the central vertical axis of the green body is L; the linear expansion coefficient of the green body of the ceramic plate when separated from the upper mold and the lower mold is ε, ε is 0.3% to 0.8%, and the predetermined angle a satisfies the following equation: After the ceramic plate body is expanded and demolded during press forming, when viewed from the side of the mating surface between the back of the body and the press mold, the point P' where the inner side vertex P of the convex surface area of ​​the body is projected onto the back of the body is outside the vertex Q of the mold.

[0011] The ceramic plate convenient for dry hanging, wherein the height H of the raised surface area is 10-30 mm. The ceramic plate convenient for dry hanging, wherein the area occupied by the raised surface area on the back of the ceramic plate is not greater than The area of ​​the back side of the ceramic plate.

[0012] The ceramic plate that is easy to dry-hang, wherein the shape of the raised surface area is a rectangle or a triangle or a combination of the two.

[0013] The ceramic plate that is easy to dry hang, wherein the volume density of the ceramic plate is 2.1-2.4 g / cm 3 .

[0014] The ceramic plate that is easy to dry hang, wherein the volume density of the ceramic plate is 1.70-1.95 g / cm 3 .

[0015] A mold for a ceramic plate that is easy to dry-hang, the mold being made through the following process: the size of the ceramic plate is enlarged by a first predetermined ratio to adapt to the requirements of edge grinding and cutting to design the semi-finished product size of the ceramic plate body after firing, and then the sizes of the upper mold and the lower mold are designed according to a second predetermined ratio of the firing shrinkage rate of the ceramic plate body formula. The upper surface of the lower mold is opposite to the concave and convex shape on the back of the ceramic plate, and the lower surface of the upper mold is flat. The upper mold and the lower mold are respectively installed on the ceramic press of the production line.

[0016] The mold for the ceramic plate that is convenient for dry hanging, wherein the first predetermined ratio is 1% to 3%, and the second predetermined ratio is 8.5% to 10.5%.

[0017] A method for manufacturing the ceramic plate that is convenient for dry hanging comprises the following steps:

[0018] Step 1, mold design: using the mold;

[0019] Step 2: Placing the material in the mold cavity of the ceramic press through the plating mechanism;

[0020] Step 3: Pressing: After the upper and lower molds set on the ceramic press are combined to form a green body, a robot is used to suck the green body out of the mold cavity, and then the green body is turned over so that the shape of the green body faces upwards;

[0021] Step 4: Drying: Drying the formed green body;

[0022] Step 5: Firing and forming.

[0023] Beneficial effects:

[0024] 1. The present invention provides a ceramic plate that is easy to dry-hang. At least two raised surface areas are provided on the back of the ceramic plate. From the cross-section of the ceramic plate, an innovative design of a lateral inward slope is adopted, in which the inner side edges of the raised surface areas form a predetermined angle with respect to the central vertical axis of the ceramic plate. The above structure enables the dry-hanging buckle kit to clamp the lateral inward concave slope of the raised surface area without falling off, making the dry hanging more secure and having a higher safety factor. Compared with the method in the prior art that requires secondary processing to form a lateral inward slope groove, the lateral inward slope structure of the present invention is an integrated dry-pressed molding, has higher safety performance, and can be applied to curtain wall dry hanging.

[0025] 2. The present invention provides a manufacturing method and mold for ceramic panels that are easy to dry-hang. First of all, the present invention is achieved through innovative design and preparation of the mold, especially (from the cross-section of the ceramic panel) using the inner side of the raised surface area to form a predetermined angle of 0°<a≤15° relative to the central vertical axis of the ceramic panel, and the lower mold is reversely designed for the ceramic panel product with a lateral inward slope structure facing the central vertical axis, and is formed in a reverse-strike manner with the lower surface of the upper mold as an overall plane. The contact surface between the upper mold and the blank is a plane, so there is no collision and damage to the top angle of the raised surface area of ​​the blank at the moment of rising and separation of the upper mold. Moreover, because the blank of the ceramic panel has the characteristic of expanding toward the surrounding during the demolding link, the design of this angle of the present invention also fully considers its matching with the expansion rate of the blank, which can ensure that the concave and convex molding surface on the upper surface of the lower mold and the concave and convex molding surface of the blank are in an easy-to-demold state during the pressing process.

[0026] Secondly, the back-pressing method of the present invention does not require pre-shaping of the powder in the mold cavity of the ceramic press, because the upper surface of its lower mold is a concave-convex shaping surface, so it is only necessary to use the conventional one-time flat spreading method to fill the mold cavity with powder to press out a green body containing a predetermined designed convex surface area; it is well known in the industry that flat spreading is the most efficient and simple spreading method in the ceramic tile production process. The innovative design of the present invention meets the above-mentioned one-time spreading and predetermined shaping, which not only produces a predetermined innovative design effect, but also reduces the difficulty of production technology and improves production efficiency.

[0027] Again, the manufacturing method of the present invention innovatively adopts a predetermined blank suction and turning method combined with a back-punching method. Because the concave and convex molding surface of the blank in the back-punching pressing method is downward, compared with the conventional blank pushing method used in the prior art, direct pushing will damage the molding surface, and without turning the blank, the concave and convex molding surface is downward and the next step cannot be carried out. Therefore, the present invention uses a predetermined blank suction and turning method to suck the blank vertically upward after demolding and move it out of the ceramic press mold cavity before turning the blank, so that the molding surface of the blank is upward, thereby ensuring the integrity of the blank and the stability of production. This is an innovative embodiment. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 This is a schematic structural diagram of a ceramic plate (with the back facing upwards) that is convenient for dry hanging provided by the present invention.

[0029] Figure 2 for Figure 1 side view.

[0030] Figure 3 This is a schematic cross-sectional view of a green body of a ceramic plate that is convenient for dry hanging provided by the present invention.

[0031] Figure 4 A schematic cross-sectional view of the back surface of a green body of a ceramic plate that is convenient for dry hanging provided by the present invention and the mating surface of a press mold.

[0032] Figure 5 This is a schematic diagram of a green body of a ceramic plate that is convenient for dry hanging provided by the present invention in a state where it is pressed and not demoulded.

[0033] Figure 6 This is a schematic diagram of the state of the green body of the ceramic plate that is convenient for dry hanging provided by the present invention after being pressed and demoulded.

[0034] Figure 7 for Figure 6 Enlarged schematic diagram of part I in the middle.

[0035] Figure 8 This is a schematic diagram of the back side of the ceramic plate of Example 1.

[0036] Figure 9 for Figure 8 Cross-sectional view of the middle MM.

[0037] Figure 10 Schematic diagram of the connection of the ceramic plate of Example 1 during dry hanging application.

[0038] Figure 11 This is a schematic diagram of the back side of the ceramic plate of Example 2.

[0039] Figure 12 for Figure 11 Cross-sectional view of NN.

[0040] Figure 13 Schematic diagram of the connection of the ceramic plate of Example 2 during dry hanging application.

[0041] Figure 14 This is a schematic diagram of the back side of the ceramic plate of Example 3.

[0042] Figure 15 Schematic diagram of the connection of the ceramic plate of Example 3 during dry hanging application.

[0043] Explanation of the main component symbols: 1-main body flat layer, 2-raised surface area, 3-dry hanging support connecting frame. DETAILED DESCRIPTION

[0044] The present invention provides a ceramic panel that facilitates dry hanging, as well as a manufacturing method and mold thereof. To further clarify the objectives, technical solutions, and effects of the present invention, the present invention is further described below with reference to the accompanying drawings and examples. It should be understood that the specific examples described herein are intended only to illustrate the present invention and are not intended to limit the scope of protection of the present invention.

[0045] See also Figure 1 、 2 The present invention provides a ceramic plate that is easy to dry-hang. The back of the ceramic plate has a concave-convex shape, and two raised surface areas are arranged along the periphery of the back of the ceramic plate. The inner side surfaces of the raised surface areas are relatively inclined.

[0046] See also Figure 3 The predetermined angle a formed by the inner side of the raised surface area of ​​the ceramic plate body and the vertical axis of the center of the body is a predetermined angle a, the distance from the inverted slope vertex (i.e., the inner side vertex) of the raised surface area of ​​the ceramic plate body to the vertical axis of the center of the body is L, the linear expansion coefficient of the ceramic plate body when separated from the upper mold and the lower mold is ε, ε is 0.3% to 0.8%, and the predetermined angle a satisfies the following equation: It should be noted that the predetermined angle a and the height H of the raised surface area jointly determine the degree to which the inner side edge of the raised surface area is tilted inward. According to the degree of expansion and deformation of the ceramic plate blank to release the internal stress, it is necessary to ensure that the inwardly inclined surface of the raised surface area can be separated from the corresponding inclined surface of the mold so as to demold in the vertical direction without damaging the corners of the inner inclined surface of the raised surface area. The predetermined angle a within the above range fully considers factors such as the linear expansion rate of the ceramic plate blank, the height H of the raised surface area, and the distance L from the raised surface area to the vertical axis of the center of the ceramic plate, to ensure that the ceramic plate blank is easy to demold after being pressed and formed, and to facilitate the complete separation of the position of the raised surface area of ​​the blank and the recessed position of the mold, so as to avoid incomplete demolding, which may cause the top corner of the raised surface area to be damaged due to collision. For further information, please refer to Figure 4-Figure 7 After the ceramic plate blank is expanded and demolded during press forming, the point P' where the inner side vertex P of the raised surface area of ​​the blank is projected onto the back of the blank is outside the vertex Q of the mold. When the blank formed by the ceramic press is separated from the mold, the entire blank tends to release its internal stress, causing the raised surface area to expand in a direction away from the center of the ceramic plate and move slightly. During the rapid separation of the blank and the mold in the preferred embodiment of the present invention, the entire blank expands uniformly to the surrounding area and releases internal stress. After expansion, the overall size of the blank within the above-mentioned linear expansion coefficient range increases by 0.5% to 1.5%, and a predetermined angle a is limited to 15°. The predetermined angle a matches the expansion rate of the blank. During the separation of the blank from the mold, the lateral inward slope groove of the blank can be completely separated from the mold, making demolding easy, which is beneficial to protecting the lateral inward slope groove and preventing its structure from being damaged during demolding due to expansion. This ensures that after dry pressing, the deformation distance of the green body during the process of releasing internal stress is sufficient to ensure that the inclined position of the raised surface area of ​​the green body can be smoothly released from the mold. In this way, the inclined surface of the raised surface area can be maintained during demolding, preventing the mold from knocking off the corners of the inner inclined surface. After subsequent firing and forming, the ceramic plate, especially large ceramic plates, can form an inner inclined surface that is convenient for dry hanging, making it more suitable for dry hanging. No secondary processing such as grooving of the ceramic plate is required, which can enhance the reliability of dry hanging.

[0047] In a preferred embodiment of the present invention, the ceramic plate is provided with at least two raised surface areas and a predetermined angle of the lateral inward slope formed on the raised surface area, which cooperates with the dry hanging buckle kit and the dry hanging support connecting frame 3, such as Figure 10As shown, the ceramic plate and the wall form at least two supports, and the lateral inward slope structure enables the dry hanging buckle kit to clamp the lateral inward concave slope on the raised surface area without falling off, making the dry hanging more firm and the safety factor higher. Compared with the processing technology of the ceramic plate in the prior art that requires secondary processing to form the lateral inward slope groove, the ceramic plate provided by the present invention is dry-pressed in one piece and does not require secondary processing, so it will not damage the ceramic plate body, and the safety is more guaranteed. And the distance between the highest point (vertex) of the raised surface area and the back of the ceramic plate, that is, the height H of the raised surface area is 10-30mm; the distance between the raised surface area and the back of the ceramic plate is high, that is, the thickness of the raised surface area is thicker. Compared with the height of the concave and convex patterns on the back of the existing ceramic tiles of only 1-5mm, the height of the raised surface area formed by the ceramic plate of the present invention is higher, the structural rigidity is stronger, and it can be applied to curtain wall dry hanging.

[0048] Furthermore, the area occupied by the raised surface area on the back of the ceramic plate is not greater than The area of ​​the rear side of the ceramic plate. The area of ​​the raised surface is large enough to ensure the formation of the lateral inward slope groove while also ensuring the structural strength of the raised surface, providing a more reliable installation position for the installation of the dry hanging clip kit.

[0049] Furthermore, the raised area is a rectangle (see Figure 8 ), triangle (see Figure 11 ), or a combination of rectangle and triangle (see Figure 14 The raised surface areas may be arranged in a discrete structure or in a strip-shaped structure, but are preferably arranged in relative positions and at a predetermined distance from the center of the ceramic plate. Otherwise, the movement distance of the raised surface areas caused by the expansion of the ceramic plate body when releasing internal stress may not be sufficient to ensure qualified demolding, that is, without touching and damaging the corners of the inner inclined surface of the raised surface areas.

[0050] In each specific embodiment, Figure 1 Shown are two strip-shaped raised surface areas, whose inner sides are inclined relative to each other and are distributed on both sides of the symmetrical sides of the back side of the main flat layer of the square ceramic plate.

[0051] like Figure 8 (Right now Figure 1In the example shown in the back plan view of the main body flat layer 1 of the ceramic plate, two symmetrical rectangular raised surface areas 2 are distributed along the upper and lower edges. The example size of the main body flat layer 1 is a square with a side length of 1000mm. A raised surface area 2 with a length of 1000mm (i.e., the side length of the main body flat layer 1) and a width of 200mm is provided on the upper and lower edges of the back of the main body flat layer 1 and starting from the upper and lower edges toward the center of the plate. The inner sides of the two raised surface areas 2 are relatively inclined, as shown in FIG. Figure 9 As shown, Figure 8 As shown in the cross-sectional view of MM, the height of the raised surface area is 10 mm, the thickness of the main flat layer 1 is 10 mm, and the predetermined angle of inclination of the inner side surface is a=13°. The area of ​​the raised surface area 2 is large enough, so the strength of the raised surface area 2 is also higher.

[0052] When the ceramic plate is dry-hanging assembled in the embodiment of the present invention, the dry-hanging support connecting frame 3 can be set and adjusted to adopt various possible support structures, such as Figure 10 As shown, the hook is as Figure 8 When the ceramic panels are shown, the dry hanging support connecting frame 3 (usually a metal frame, such as a steel frame) can be adjusted to form tension on the upper and lower sides of the back of each ceramic panel, and the support connecting frame 3 is clamped into the inner inclined surface of the raised surface area 2, so that the hanging can be achieved securely. In addition, the construction does not require additional secondary processing of the ceramic panels, which is more convenient.

[0053] like Figure 11 The back side schematic diagram of the example shown, an isosceles right triangle convex area 2 is set on each of the four corners of the back side of the main flat layer 1. The example uses a square ceramic plate with a side length of 1000mm. An isosceles right triangle convex area 2 is set on each of the four corners of the back side of the main flat layer 1 and from the corner as the starting point to the center of the ceramic plate. The inner side of the convex area 2 is inclined relative to the center of the ceramic plate (that is, the inner side of the convex area 2 on the same diagonal line is relatively inclined). See FIG. Figure 12 As shown, Figure 11 In the cross-sectional view of NN shown, the raised surface area 2 has an inward inclination angle a=8°, the thickness of the main flat sheet 1 is 5mm, and the height of the raised surface area 2 is 10mm. The raised surface area 2 is thicker than the main flat sheet 1. This design not only strengthens the support strength of the raised surface area 2, but also reduces the overall weight of the ceramic plate and improves the bearing capacity of the dry hanging support connection frame. Figure 13 As shown, this example uses the dry hanging support connecting frame 3 to hang the construction method. Any raised surface area with an inclination angle relative to the center of the ceramic plate can be hung with pre-tension outward by the corresponding support connecting frame.

[0054] like Figure 14 and Figure 15 As shown, in the ceramic plate of the preferred embodiment of the present invention, a triangular raised surface area with an inner side inclined toward the center of the plate can be set at the two lower corners, and a rectangular raised surface area with an inner side inclined downward can be set at the top. This design can facilitate the use of a triangular dry-hanging support connecting frame 3 structure, thereby utilizing the stability principle of the triangle to strengthen the hanging of the ceramic plate.

[0055] In summary, each design scheme for the raised surface area 2 of the ceramic plate can adopt different distribution methods according to the different actual settings of the dry hanging support connecting frame 3, thereby facilitating on-site dry hanging construction.

[0056] Furthermore, the volume density of the ceramic plate is 2.1 to 2.4 g / cm 3 Preferably, the volume density of the ceramic plate is 1.70-1.95 g / cm 3 2.1~2.4g / cm 3 The volume density is the normal volume density of ceramic plates. For two ceramic plates of the same volume, if the volume density is small, the mass is lighter, and vice versa, if the density is large, the mass is heavier. The volume density is 1.70~1.95g / cm 3 The relative bulk density of ceramic plates is 2.1 to 2.4 g / cm 3 For ceramic panels, they are lighter in weight and can reduce the pulling force on components such as the dry hanging support connecting frame, making the dry hanging support connecting frame components more durable and improving the safety factor. The volume density is 1.70~1.95g / cm 3 The ceramic plate has a light load on the wall, providing a curtain wall material with a higher safety factor and better physical and chemical properties for curtain wall dry hanging applications. The volume density is 1.70~1.95g / cm 3 The ceramic plate can be formed by pressing a lightweight green body powder in a ceramic press at a certain molding pressure.

[0057] The present invention also provides a method for manufacturing a ceramic plate that is convenient for dry hanging. A preferred embodiment includes the following steps:

[0058] Step 1: Raw material preparation: Prepare the ceramic raw materials required for producing the dry-hanging ceramic slabs. Specifically, the ceramic raw materials have a moisture content of less than 9%. The ceramic raw materials may be conventional ceramic powders that have passed through a 60-mesh sieve with a sieve residue of at least 85%, or a mixture of conventional ceramic powders that have passed through a 60-mesh sieve with a sieve residue of at least 85% and particles of a predetermined grade.

[0059] Step 2, mold design: enlarge the size of the ceramic plate by a first predetermined ratio, such as but not limited to 1% to 3%, as a requirement for adapting to edge grinding and cutting, and design the size of the semi-finished product of the ceramic plate after firing. Then, design the size of the upper mold and the lower mold according to the second predetermined ratio of the firing shrinkage rate of the ceramic plate body formula, such as but not limited to 8.5% to 10.5%, wherein the upper mold and the lower mold are designed in reverse according to the predetermined shape of the lower surface of the ceramic plate, that is, the concave and convex surface of the upper surface of the lower mold and the lower surface of the upper mold are a flat reverse combination, and the upper and lower molds and the concave and convex surfaces of the ceramic plate are a matching design corresponding to one male and one female, and the upper mold and the lower mold are respectively installed on the ceramic press of the production line.

[0060] Step 3: Placing material in the mold cavity of the ceramic press through the plating mechanism.

[0061] Fabrication method 1: Use conventional one-time fabrication mechanism to directly lay the fabric flat in the mold cavity to form an overall flat layout material.

[0062] Method 2: A mechanically and digitally controlled digital spreading mechanism pre-forms the color zones and / or line patterns. Ceramic powder is first applied to fill the recessed areas of the lower mold within the mold cavity. The aforementioned pattern is then applied to the mold cavity to create a flat, planar pattern. This method utilizes CNC technology to pre-form the pattern in predetermined zones, enabling the production of blanks with color zones and / or line patterns. By pre-filling the recessed areas, this method prevents the color zones and / or line patterns from falling into the recessed areas of the lower mold during mold pressing, resulting in uneven patterning and a messy pattern. This method ensures the desired pattern is perfectly rendered.

[0063] Step 4: Pressing: After the upper and lower molds set on the ceramic press are combined and pressed into a green body, a robot is used to suck the green body out of the mold cavity, and then the green body is turned over so that the shape of the green body faces upward. The inner side of the raised surface area of ​​the green body of the ceramic plate of the present invention forms a predetermined angle of 0°<a≤15° with the central vertical axis (the predetermined angle a is calculated through comprehensive and coordinated matching based on the linear expansion rate of the green body of the ceramic plate, the height of the raised surface area, and the distance from the raised surface area to the central vertical axis. The height of the raised surface area and its distance from the center position can be adjusted after setting the predetermined angle).

[0064] The side edge formed by the predetermined angle a of 0°<a≤15° here is a lateral inward concave edge (inverted slope) design. If a positive striking method is adopted, that is, the lower surface of the upper mold is a concave-convex modeling surface, and the upper surface of the lower mold is a plane, then at the moment of the upper mold rising and separating, the blank has not fully expanded, and it is easy to collide and damage the inverted slope top angle of the convex surface area. Therefore, the present invention adopts a reverse striking combination in which the upper surface of the lower mold is a concave-convex modeling surface and the lower surface of the upper mold is an overall flat surface, which can effectively avoid the phenomenon that the blank has not fully expanded and collides with the inverted slope top angle of the convex surface area at the moment of the upper mold rising and separating, causing damage.

[0065] In addition, after forming by this pressing method, the concave and convex surface of the blank is facing downward, and the conventional brick pushing method will damage the surface. If the blank is not turned over, it cannot run on the glaze line in the subsequent process. Therefore, a robot can be set up to suck the blank vertically upward and move it out of the mold cavity of the press, and then turn the blank over and place it on the glaze line, so that the concave and convex surface of the blank is facing upward, thereby ensuring the integrity of the blank and the stability during subsequent transmission.

[0066] Step 5: Drying: In a preferred embodiment, the formed green body is dried at a temperature of 180° C. for 75 minutes. Specifically, the moisture content of the green body after drying is less than 0.3%.

[0067] Step 6: Firing: In this example, the green body is placed in a kiln with a maximum temperature of 1140°C to 1220°C and fired for 70 minutes to obtain a semi-finished product.

[0068] Step 7: Processing: Cooling, cutting and grinding edges to produce ceramic panels that are easy to dry hang.

[0069] Example 1

[0070] See also Figure 8 、 Figure 9 In this embodiment, a ceramic plate having a main body side length of 1000 mm and a main body flat green sheet 1 having a thickness of 10 mm is used as an example to illustrate its manufacturing method. A raised surface area 2 having a length of 1000 mm, a width of 200 mm, and a height of 10 mm is provided on the upper and lower edges of the back side of the main body flat green sheet 1, with the upper and lower edges being the starting points and moving toward the center of the plate. Furthermore, a predetermined angle a formed between the inner side of the raised surface area 2 and the vertical direction (the vertical direction being parallel to the central vertical axis) is 13°. The specific steps are as follows:

[0071] (1) Mold design: According to the predetermined shape of the back of the ceramic plate to be produced, a reverse design is performed to produce a lower mold with a side length of 1125 mm, and an upper mold with the same size as the lower mold and a flat lower surface is produced. Both the upper mold and the lower mold are installed on the ceramic press on the production line.

[0072] (2) Raw material preparation: prepare a green body material, wherein the moisture content of the green body material is 8%, the powder particle size passes through a 60-mesh sieve, and the sieve residue reaches more than 85%.

[0073] (3) Machine preparation: Install a conventional primary feeding mechanism connected to the ceramic press, and feed the blank material from step (2) into the feeding hopper of the feeding mechanism.

[0074] (4) Distribution: The green body material in the distribution hopper is distributed into the distribution grid, and the green body powder is framed by the distribution grid to form an overall plane layout in the ceramic press mold cavity.

[0075] (5) Pressing: The ceramic press presses the flat layout material in the mold cavity into a blank with a side length of 1130 mm (the linear expansion rate of the blank after pressing is about 0.5%), the thickness of the main flat blank layer 1 is 11 mm, and a raised surface area 2 with a length of 1130 mm, a width of 225 mm and a height of 11 mm is set on the upper and lower edges of the back of the main flat blank layer 1 and starting from the upper and lower edges to the center of the blank. The inner side edge of the raised surface area 2 forms a predetermined angle a of 13° with the vertical direction (the vertical direction is parallel to the central vertical axis). Then, the blank is sucked up vertically and moved out of the ceramic press mold cavity by a robot in combination with a suction method. The robot turns the blank over so that the concave and convex shape of the brick blank faces upward, and the cloth grid continues to perform the next round of operation under the return cloth mechanism.

[0076] (6) Drying: The formed green body is dried in a drying kiln at a temperature of 180°C for 75 minutes. After drying, the moisture content of the green body is less than 0.3%.

[0077] (7) Firing and molding: Firing in a kiln at a maximum temperature of 1140℃~1220℃ for 70 minutes to obtain a semi-finished product.

[0078] (8) Processing: The semi-finished product is cooled and edge-cut, and the main body side length is 1000 mm, the thickness of the main body flat layer 1 is 10 mm, and a raised surface area 2 with a length of 1000 mm, a width of 200 mm, and a height of 10 mm is set on the upper and lower edges of the back of the main body flat layer 1 and starting from the upper and lower edges toward the center of the plate. The inner side edge of the raised surface area 2 forms a predetermined angle a of 13° with the vertical direction (the vertical direction is parallel to the central vertical axis) to form a ceramic plate.

[0079] Example 2

[0080] See also Figure 11 and Figure 12In this embodiment, a ceramic plate having a main body side length of 1000 mm and a main body flat layer 1 having a thickness of 5 mm is taken as an example. An isosceles right-angled triangle-shaped raised surface area 2 is provided on each of the four corners on the back side of the main body flat layer 1 and starting from the corner toward the center of the ceramic plate. The thickness (height) of the raised surface area is 10 mm, and the predetermined angle a formed by the inner side edge of the raised surface area 2 and the vertical direction (the vertical direction is parallel to the central vertical axis) is 8°. The ceramic plate can be obtained by adopting the same manufacturing method as in Example 1.

[0081] Example 3

[0082] On the basis of Examples 1 and 2, the raised surface area of ​​the ceramic plate in this embodiment is a combination of rectangles and triangles, such as Figure 14 As shown, a ceramic plate having a raised surface area that is a combination of rectangles and triangles is obtained.

[0083] Example 4

[0084] On the basis of Example 1, the composition of the green body material described in this embodiment is a mixture of powder that has passed through a 60-mesh sieve and has a sieve residue of more than 85% and particles of predetermined gradation and color. The manufacturing method is the same as that of Example 1, and a ceramic plate with a particle effect in the green body can be obtained.

[0085] Example 5

[0086] On the basis of Example 1, this embodiment uses powder that has passed through a 60-mesh sieve and has a sieve residue of more than 85%, or a mixture of the above powder and particles of predetermined grading and color as the main material, and further uses powder of a color different from that of the main material as the line material and / or color zone material. The predetermined belt in the mechanically and digitally controlled digital spreading mechanism is used to simultaneously apply the predetermined color zone and / or line material during the process of spreading the material to form a layout material containing the predetermined color zone and / or line, and first applies the powder once to fill the concave pit on the lower mold in the mold cavity, and then applies the above layout material in the mold cavity to form an overall plane layout material, and then undergoes the same subsequent manufacturing method as Example 1 to obtain a ceramic plate containing color zones and / or line effects in the blank.

[0087] In summary, the ceramic plate of the present invention is provided with at least two raised surface areas on its back side. From the cross section of the ceramic plate, an innovative design of a lateral inward slope is adopted in which the inner side of the raised surface area forms a predetermined angle of 0°<a≤15° relative to the central vertical axis of the ceramic plate. The above structure enables the dry hanging buckle kit to clamp the lateral inward concave slope of the raised surface area without falling off, making the dry hanging more firm and having a higher safety factor. Compared with the prior art method that requires secondary processing to form a lateral inward slope groove, the lateral inward slope structure of the present invention is an integrated dry pressing molding with higher safety performance; and the height of the raised surface area formed by the ceramic plate of the present invention is higher and the structural rigidity is stronger, so it can be used for curtain wall dry hanging. The ceramic plate adopts a lightweight green body powder formula to make its volume density reach 1.70~1.95g / cm 3 , which makes the ceramic panels lighter, reduces the pulling force on components such as dry-hanging brackets, makes the dry-hanging bracket components more durable, improves the safety factor, and the ceramic panels have a lighter load on the wall, providing a curtain wall material option with a higher safety factor and better physical and chemical properties for curtain wall dry-hanging applications.

[0088] The manufacturing method and mold of the ceramic plate that is easy to dry-hang of the present invention, first of all, the present invention is through the innovative design and preparation of the mold, especially (from the cross-section of the ceramic plate) the inner side of the raised surface area forms a predetermined angle of 0°<a≤15° relative to the central vertical axis of the ceramic plate, and the lower mold is reversely designed for the ceramic plate product with a lateral inward slope structure facing the central vertical axis, and the predetermined concave position and / or convex position of the lower mold are a separate design that can be predetermined to rise or fall, and are formed in a reverse-punching manner with the lower surface of the upper mold as an integral plane. The contact surface between the upper mold and the blank is a plane, so there is no collision and damage to the top angle of the raised surface area at the moment of rising and separation of the upper mold. Moreover, because the blank of the ceramic plate has the characteristic of expanding toward the surrounding during the demolding link, the design of this angle of the present invention also fully considers its matching with the expansion rate of the blank, which can not only ensure that the concave and convex molding surface on the upper surface of the lower mold and the concave and convex molding surface of the blank are in an easy-to-demold state during the pressing process, but also ensure that its raised surface area will not collide with any part of the mold during the expansion of the blank.

[0089] Secondly, the back-pressing method of the present invention does not require pre-shaping of the powder in the mold cavity of the ceramic press, because the upper surface of its lower mold is a concave-convex shaping surface, so it is only necessary to use the conventional one-time flat spreading method to fill the mold cavity with powder to press out a green body containing a predetermined designed convex surface area; it is well known in the industry that flat spreading is the most efficient and simple spreading method in the ceramic tile production process. The innovative design of the present invention meets the above-mentioned one-time spreading and predetermined shaping, which not only produces a predetermined innovative design effect, but also reduces the difficulty of production technology and improves production efficiency.

[0090] Again, the manufacturing method of the present invention innovatively adopts a predetermined blank suction and turning method combined with a back-punching method. Because the concave and convex molding surface of the blank in the back-punching pressing method is downward, compared with the conventional blank pushing method used in the prior art, direct pushing will damage the molding surface, and without turning the blank, the concave and convex molding surface is downward and the next step cannot be carried out. Therefore, the present invention uses a predetermined blank suction and turning method to suck the blank vertically upward after demolding and move it out of the ceramic press mold cavity before turning the blank, so that the molding surface of the blank is upward, thereby ensuring the integrity of the blank and the stability of production. This is an innovative embodiment.

[0091] It is well known in the industry that during the pressing process, the green body of the ceramic plate is pressed and formed by the upper and lower dies of the press under the joint force of six sides in the mold cavity. At the time of final pressing, the green body of the ceramic plate has the same internal stress. During the demolding process of the green body, the upper and lower dies clamp the formed green body out of the mold cavity, and in the process of rapid separation of the upper die and the green body, the entire green body expands uniformly to the surrounding area and releases internal stress. The overall size of the green body after expansion increases by about 0.5%-1.5%. Therefore, the back of the general ceramic plate can basically only have a shallow texture or a regular trapezoidal protrusion. This kind of shape is conducive to demolding during the pressing process and will not damage the green body.

[0092] Because the blank has the characteristic of expanding when it leaves the mold cavity, and the mold does not change, if the blank is pre-set with an inverted trapezoidal protrusion facing inward on one side, and the predetermined angle between its lateral inner concave edge and the vertical direction is greater than 15°, its expansion rate does not match the predetermined angle, and the protruding position of the blank and the concave position of the mold are not completely separated, resulting in incomplete demolding, causing the top corner of the protrusion to be easily damaged. Therefore, the preferred embodiment of the present invention fully considers the degree of expansion of the blank of the ceramic plate during the manufacturing process of the ceramic plate, and pre-designs the height H of the protruding surface area and the predetermined tilt angle a according to the different sizes of ceramic plates, the materials used, and the expansion rate of the blank during dry pressing demolding through calculation or testing, thereby determining the corresponding structure of the mold used. Therefore, the preferred embodiment of the present invention also provides a mold corresponding to the processing and manufacturing of the ceramic plates of the present invention.

[0093] It is understandable that those skilled in the art can make equivalent substitutions or changes based on the technical solution and inventive concept of the present invention, and all such changes or substitutions should fall within the scope of protection of the present invention.

Claims

1. A ceramic plate that is easy to dry hang, characterized in that: The back of the ceramic plate has a concave-convex shape, and at least two convex areas are provided along the periphery of the back of the ceramic plate; Before being fired and formed, the ceramic plate is a green body made of ceramic powder through integrated dry pressing. From the cross-section of the green body of the ceramic plate, the inner side of the raised surface area is inclined relative to the central vertical axis of the green body, and the predetermined angle a formed with the central vertical axis is set to 0°<a≤15°. The distance from the vertex of the inner side of the raised surface area to the central vertical axis of the green body is L. The linear expansion coefficient of the green body of the ceramic plate when separated from the upper mold and the lower mold is ε, and ε is 0.3% to 0.8%. The predetermined angle a satisfies the following equation: , the height H of the raised surface area is 10-30 mm; After the green body of the ceramic plate is expanded and demolded during press forming, when viewed from the side of the mating surface between the back of the green body and the press mold, the point P' where the inner side vertex P of the raised surface area of ​​the green body is projected onto the back of the green body is outside the mold vertex Q; The inner side of the raised surface area forms a lateral inward slope structure with a predetermined angle relative to the central vertical axis of the ceramic plate; the lower surface of the upper mold is flat, and the upper surface of the lower mold is opposite to the concave and convex shape on the back of the ceramic plate; The volume density of the ceramic plate is 1.70-1.95 g / cm 3 .

2. The ceramic plate convenient for dry hanging according to claim 1, characterized in that: The area occupied by the raised surface area on the back of the ceramic plate is not greater than The area of ​​the back side of the ceramic plate.

3. The ceramic plate convenient for dry hanging according to claim 1, characterized in that: The shape of the raised surface area is a rectangle or a triangle or a combination of the two.

4. The ceramic plate convenient for dry hanging according to claim 1, characterized in that: The mold for the ceramic plate that is easy to dry-hang is made through the following process: the size of the ceramic plate is enlarged by a first predetermined ratio to adapt to the requirements of edge grinding and cutting to design the semi-finished product size of the ceramic plate body after firing, and then the sizes of the upper mold and the lower mold are designed according to the second predetermined ratio of the firing shrinkage rate of the ceramic plate body formula. The upper surface of the lower mold is opposite to the concave and convex shape on the back of the ceramic plate, and the lower surface of the upper mold is flat. The upper mold and the lower mold are respectively installed on the ceramic press of the production line.

5. The ceramic plate convenient for dry hanging according to claim 4, characterized in that: The first predetermined ratio is 1% to 3%, and the second predetermined ratio is 8.5% to 10.5%.

6. A method for manufacturing a ceramic plate that is convenient for dry hanging as claimed in claim 4 or 5, characterized in that: The following steps are involved: Step 1, mold design: using the mold; Step 2: Placing the material in the mold cavity of the ceramic press through the plating mechanism; Step 3: Pressing: After the upper and lower molds set on the ceramic press are combined to form a green body, the green body is sucked out of the mold cavity and then turned over so that the shape of the green body faces upwards; Step 4: Drying: Drying the formed green body; Step 5: Firing and forming.

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