A concave-convex ceramic plate formed by positive punching and dry pressing in one step and a manufacturing method thereof

Abstract

The present application relates to the technical field of building ceramics, and particularly relates to a positive pressing type integrated dry-pressing formed concave-convex ceramic plate and a manufacturing method thereof. The present application adopts a method of pre-arranging raw materials to match a predetermined molding die of a press, and the arrangement of the powder materials has preliminarily formed a preliminary molding corresponding to the press die before pressing, which can keep the consistency and uniformity of the overall raw materials when being pressed. Compared with the conventional matching of the overall planar arrangement of materials and the molding die, the contact range of the convex position of the die and the overall planar material is denser, and the contact range of the concave position of the die and the overall planar material is relatively lower in density, thereby forming a large difference in density, which is easy to be layered and to produce cracks, and thus the yield is low. The pre-arranged materials and the molding die of the present application can be well matched, and the plate product has the characteristics of high density consistency, high strength and good integration.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of architectural ceramics, in particular to a concave-convex ceramic plate formed by positive punching and integrated dry pressing and a manufacturing method thereof. BACKGROUND

[0002] With the rapid development of society, people's living standards have also been greatly improved. In the interior decoration, people no longer simply focus on the decorative effect brought by floor paving or wall paving, but also pay more attention to the combination of practicality and decoration on the countertops or utensils in the kitchen and bathroom. The countertops of the existing hand-washing table, bathroom basin, dish-washing basin or stove, tea set in the kitchen and bathroom, and the specific countertops in the laboratory, etc. are generally made by carving, polishing, water jet cutting technology or splicing method when they need to be made into predetermined shapes or installed with related accessories. Most of them are mainly processed by using stone or quartz stone, artificial stone. The use of stone processing requires a large amount of natural stone resources, which causes great damage to the disordered exploitation of ecology. The use of quartz stone or artificial stone for processing has poor stain resistance and is prone to deformation. At the present stage, low-carbon development and resource-saving development are advocated. Seeking better substitutes is the future development trend. On the other hand, ceramic plates have achieved great success in replacing natural stone in the field of floor paving and wall paving due to their superior physical and chemical properties, thereby driving the rapid development of the building ceramic industry. However, with the rapid development of equipment technology and material technology, developing products for application in more home fields will also be one of the future directions of the ceramic industry.

[0003] In view of the above needs, relevant ceramic industry manufacturers are also researching the application of ceramic plate in existing home kitchen and bathroom. The surface of the existing ceramic plate is a complete plane or a shallow concave-convex surface. If various products such as kitchen and bathroom plates, tea sets, laboratory plates, etc. with predetermined shapes and deep concave-convex shapes are prepared from such ceramic plates, the processing method is mainly to form various shapes by splicing. When making a concave-convex plate with a large height difference by using an integrated compression molding technology, the upper mold with a predetermined shape is used to compress the powder material with an overall flat shape to obtain the product. The inventor found that the thickness of the powder layout is basically the same, and the powder layout does not have a preliminary shape difference corresponding to the male and female matching of the molding mold. The mismatch between the powder layout and the predetermined shape of the mold causes the compactness of the green body after compression to be uneven, with large differences, easy to layer, and leads to a series of problems such as poor drainage and oxidation during the firing process, large deformation after firing, and easy cracking of the surface, and even breaking of the whole plate. In addition, there is a compression scheme using a predetermined convex rib upper mold to lay the powder material. The scheme solves the problems in the compression and firing process by using the inverted taper of the convex rib to push away and squeeze the powder material. However, this scheme is only effective when the width of the convex rib is less than 30 mm. When the width of the convex rib is greater than 30 mm, the powder material cannot be pushed away, and the uniform and dense compression of the concave-convex surface with a large area cannot be achieved.

[0004] In view of the above deficiencies, improvements need to be made in the process to produce more ceramic plates with predetermined shapes to meet the needs of standardized mass production and personalized markets. SUMMARY

[0005] In view of the deficiencies of the prior art, the purpose of the present application is to provide a positive punching type integrated dry compression molding concave-convex ceramic plate and a manufacturing method thereof, which aims to solve the problem of mismatch between the powder layout and the predetermined shape of the mold in the existing method, causing the compactness of the green body after compression to be uneven, with large differences, and easy to layer.

[0006] The technical solution of the present application is as follows:

[0007] A manufacturing method of a positive punching type integrated dry compression molding concave-convex ceramic plate, comprising the following steps:

[0008] a. Raw material preparation: preparing the raw materials needed to manufacture the concave-convex ceramic plate;

[0009] b. Mold design: designing the mold shape according to the front and back predetermined shapes of the concave-convex ceramic plate, wherein the lower surface of the upper mold is a concave-convex shaped surface, and the concave-convex shaped surface and the concave-convex shaped surface of the concave-convex ceramic plate are corresponding male and female matching design, as shown in Figures 1-3 .

[0010] c. Laying: using a laying mechanism to form a layout material of a predetermined shape in a mold cavity of a press corresponding to the shape of the upper mold;

[0011] d. Pressing: using a press to press the layout material of the predetermined shape into a green body through a mold of the predetermined shape;

[0012] e. Drying: drying the green body;

[0013] f. Sintering: sintering the dried green body to obtain a semi-finished product;

[0014] g. Processing: cooling and grinding the edges of the semi-finished product to obtain the concave-convex ceramic plate.

[0015] The method of the present application uses the layout of the raw material to match the predetermined shape of the mold of the press. The layout of the powder material before pressing has formed a preliminary shape corresponding to the male and female mold of the press. This layout can maintain the consistency and uniformity of the overall material during pressing. The green body after pressing is dense and uniform, and the bulk density is consistent. The product has the characteristics of high strength, good bending resistance, and good integrity, thereby improving the stability of the product quality.

[0016] Optionally, in step a, the raw materials required for making the concave-convex ceramic plate are prepared, and the water content of the raw materials is not higher than 9%. The raw materials are conventional ceramic powder with a sieve residue of more than 85% through a 60-mesh sieve or a mixture of these conventional ceramic powder and particles of predetermined gradation and color.

[0017] Optionally, in step b, the size of the mold is designed by the following method: the size of the concave-convex ceramic plate is enlarged by 1% to 3% to design the size of the semi-finished product after the green body of the ceramic plate is sintered, and then the shrinkage rate of the ceramic plate during sintering is designed to be 8.5% to 10.5% to design the size of the mold.

[0018] Optionally, in step b, the lower plane of the upper mold is provided with a predetermined concave plane area, and the upper plane of the lower mold is also provided with a small protrusion with a height of 1-2.5 mm higher than the small protrusion on the upper plane of the lower mold corresponding to the predetermined protrusion plane area on the lower plane of the upper mold, the area between the small protrusions (i.e., the protrusion lines corresponding to the back surface of the blank) is at the same level, and the edge of the small protrusion is designed as a slope with an angle greater than or equal to 10° with the vertical direction. The increase in the height of the small protrusions on the upper plane of the lower mold corresponding to the predetermined concave plane area on the lower plane of the upper mold (i.e., the depth of the small concave on the back surface of the blank) compared to the height of the small protrusions corresponding to the predetermined protrusion plane area on the lower plane of the upper mold (i.e., the depth of the small concave on the back surface of the blank) can reduce the actual thickness of this area of the blank, further reduce the difference in the overall actual thickness of the blank, and further improve the consistency of the overall oxidation exhaust and drainage of the blank during firing and the sintering property. The design that the area between the small protrusions (i.e., the protrusion lines corresponding to the back surface of the blank) is at the same level can make the bottom surface of the blank travel on the transmission line in a plane, and the design that the edge of the small protrusion is a slope with an angle greater than or equal to 10° with the vertical direction can facilitate the smooth demolding of the blank.

[0019] Optionally, in step c, the material distribution mechanism can be a secondary material distribution mechanism capable of distributing materials in a predetermined design area and position after a primary distribution of materials, or a mechanical and digital controlled digital material distribution mechanism / conventional material distribution mechanism.

[0020] Optionally, the material distribution method can be one of the following three methods:

[0021] Method one: a mechanical secondary material distribution mechanism with a specific design is used to form a predetermined thickness of overall planar layout in the mold cavity of the press through a material distribution grid or a moving belt primary distribution method, and then a predetermined position is stacked and distributed by a moving belt bucket to form a layout material with a predetermined shape corresponding to the molding of the upper mold of the press. The secondary material distribution mechanism is used to distribute the planar layout material with a predetermined thickness in the mold cavity of the press, and then the material with a predetermined protrusion plane is distributed to form a predetermined protrusion plane. This material distribution method has high efficiency, good flatness, simple structure, easy implementation, low failure rate, accurate material distribution control, and can be used to distribute materials of various particle sizes.

[0022] The second way is to use a mechanical and digital controlled digital cloth mechanism, and a cloth pattern file corresponding to the inverse of the molding of the upper die of the press is transmitted into the computer of the digital cloth mechanism. The cloth mechanism forms a predetermined thickness of the overall planar layout material on the conveying belt according to the cloth parameters set in the pattern file, and then performs a predetermined position superimposed cloth to form a predetermined molding layout material corresponding to the molding of the upper die. The predetermined molding layout material is sent into the cavity of the press. The cloth mechanism falls out the predetermined thickness and molding layout material corresponding to the molding of the upper die of the press on the conveying belt and is sent into the cavity of the press. In this way, the material can directly complete the preliminary molding of the layout material corresponding to the molding of the upper die of the press on the conveying belt, and the digital control technology can also perform a predetermined partitioned cloth. The pre-molding of the material formed on the belt by the nozzle, the advantage of digital technology control is that the molding can be diversified and flexibly designed, but due to the limitation of the nozzle aperture, the existing technology cannot realize the particle material with a particle size greater than 2 mm, so the use of the material is limited to a certain extent, and its efficiency is slower than the mechanical secondary cloth.

[0023] The third way is to use a conventional cloth mechanism or a mechanical and digital controlled digital cloth mechanism to directly form an overall planar layout material in the cavity of the press, and then perform a predetermined position scraping according to the molding of the upper die to form a predetermined molding layout material corresponding to the molding of the upper die of the press. This way uses a conventional way of cloth, and can also directly form a preliminary molding of the layout material corresponding to the molding of the upper die of the press in the cavity of the press. The error of the slope of the whole before and after the scraping in the cavity is large, so the thickness difference is also large, which will lead to uneven density, and it is difficult to recycle the excess material, especially when the scraping is more, the error is large, which is not conducive to the stability of the pressing molding. This way is mainly for the molding with a shallow scraping, i.e. a small concave-convex depth, so the preferred way of the present application is the first and second ways.

[0024] Through the above several cloth ways, the layout of the material can form a preliminary molding corresponding to the upper die of the press before pressing. This molding layout can maintain the consistency and uniformity of the overall material during pressing. Compared with the conventional overall planar layout material matched with the molding die, the contact range of the convex position of the die with the overall planar material is more dense during pressing, and the contact range of the concave position of the die with the overall planar material is relatively low, thereby forming a large difference in density. During demolding after pressing, the convex position of the blank corresponding to the concave position of the die is prone to delamination due to insufficient material density, and after firing, the convex position of the plate corresponding to the concave position of the die is prone to cracking due to insufficient material density, thereby reducing the yield. The pre-molding layout material of the present application can well correspond to the upper die, and the obtained plate product has the characteristics of high density consistency, high strength and good integrity.

[0025] In step d, the layout material preliminarily formed into a predetermined shape is pressed into a green body by a press through a mold with a predetermined shape, wherein the green body has an upper surface with a predetermined shape, and the pressure of the press can be 220 bar to 250 bar.

[0026] Optionally, after step e and before step f, a step of applying glaze / slip is further included, i.e., spraying / rinsing glaze / slip on the surface of the dried green body to form a surface decoration layer. The spraying / rinsing glaze / slip can be performed in the following ways:

[0027] In the first way, a layer of protective glaze is sprayed.

[0028] In the second way, a layer of glaze / slip is first sprayed, and then glaze / slip / dry granular glaze is rinsed.

[0029] Optionally, the specific gravity of the sprayed glaze / slip is 1.1 to 1.5 g / cm 3 , the specific gravity of the rinsed glaze / slip is 1.80 to 1.90 g / cm 3 , and the flow rate is 35 to 45 s.

[0030] Optionally, before or after the step of spraying / rinsing glaze / slip, inkjet printing of a predetermined pattern is performed.

[0031] Optionally, in step f, the highest temperature of the firing can be 1140℃ to 1220℃.

[0032] A concave-convex ceramic plate formed by a positive punching and dry pressing process, wherein the front surface of the concave-convex ceramic plate has at least one concave surface or convex surface, the planar size of the concave surface or convex surface is greater than or equal to 30 mm in width and greater than or equal to 100 mm in length, and the minimum difference between the concave surface and the convex surface of the concave-convex ceramic plate is greater than or equal to 3 mm.

[0033] The angle between the side of the convex surface or concave surface on the front surface of the concave-convex ceramic plate and the vertical direction is 0-75°; the top of the convex surface and the bottom of the concave surface on the front surface of the concave-convex ceramic plate are respectively in the same plane or not in the same plane; and the vertical projection of any edge of each plane of the convex surface and the concave surface on the bottom plane of the plate does not coincide. The comprehensive synergy of the angle and the position design can ensure the smooth pressing and molding of the green body and the easy demolding.

[0034] Optionally, the front surface of the concave-convex ceramic plate has at least one concave surface or convex surface, the planar size of the concave surface or convex surface is greater than or equal to 50 mm in width and greater than or equal to 100 mm in length, and the minimum difference between the concave surface and the convex surface of the concave-convex ceramic plate is greater than or equal to 5 mm.

[0035] Optionally, the back surface of the concave-convex ceramic plate is further provided with a grid-shaped concave-convex texture composed of predetermined concave lines and their surrounding convex lines, the concave depth of the concave lines on the back surface of the plate at the corresponding position of the concave area on the front surface of the plate is 0.5-1 mm, the concave depth of the concave lines on the back surface of the plate at the corresponding position of the convex area on the front surface of the plate is 2-3 mm, and the convex lines on the back surface of the plate are in the same horizontal plane and the edge of the convex lines is a slope surface with an angle greater than or equal to 10° with the vertical direction. The concave depth of the concave-convex texture on the back surface of the plate is designed according to the corresponding area of the concave-convex area on the front surface of the plate, the position with a large concave depth corresponds to the convex area on the front surface of the plate, and the position with a small concave depth corresponds to the concave area on the front surface of the plate. The thickness of the blank body is compensated to obtain a certain balance, thereby improving the consistency of oxidation exhaust and drainage and sintering property of the blank body as a whole during the firing process. The design of the convex lines in the same plane is to make the bottom surface of the blank body after demolding be flat and travel on the conveying line. The edge of the convex lines is designed as a slope surface with an angle greater than or equal to 10° with the vertical direction, which facilitates the smooth demolding of the convex lines on the back surface of the blank body without damage.

[0036] Optionally, the main body shape of the plate is any one of a triangular shape, a quadrilateral shape, a circular shape, an elliptical shape, a diamond shape, a trapezoidal shape, and a polygonal shape. The shape of the concave surface or the convex surface on the front surface of the plate is one or a combination of more than one of a triangular shape, a quadrilateral shape, a circular shape, an elliptical shape, a diamond shape, a trapezoidal shape, and a polygonal shape. The main body and the concave surface or the convex surface of the plate can be designed to have a predetermined irregular shape as needed, thereby providing a selection space of personalized and differentiated products for designers and users. It should be noted that the main body refers to the plate excluding the convex part or the plate excluding the transverse part where the concave part is located.

[0037] Optionally, the convex surface or the concave surface on the front surface of the concave-convex ceramic plate is further provided with a plurality of small grooves or small convex strips, the width of the small grooves or the small convex strips is 10-20 mm, and the depth or height is 3-10 mm. The small grooves or the small convex strips designed in this way can be used as a draining groove on a tea set table. Since the depth or height of the small grooves or the small convex strips is relatively small and the arrangement is uniform, the density of the overall powder layout of the blank body is not affected, so it is not necessary to arrange the powder in a specific way, but only to press the flatly arranged powder through a predetermined molding mold to form the predetermined small grooves or the small convex strips. It is commonly known in the industry that flat arrangement is the most efficient and convenient arrangement method in the production process of porcelain tiles. The innovative design in this place satisfies the predetermined effect and realizes the reduction of the control difficulty of the production technology and the improvement of the efficiency.

[0038] Optionally, the convex surface or the concave surface on the front surface of the concave-convex ceramic plate is further provided with a small concave or a small convex.

[0039] Optionally, the plate material is pure color or mixed color containing particles or also containing predetermined color zones / lines.

[0040] Optionally, the surface of the concave-convex ceramic plate material also contains glaze / paste or / and contains a decorative effect layer formed by inkjet pattern.

[0041] Optionally, the concave or convex surface of the front surface of the concave-convex ceramic plate material can be used as the back surface of the product. When the concave or convex surface is used as the back surface, the convex part can be used for slotting or punching application or assembling a hanging part for dry hanging, and the concave part can increase the strength of the plate material, greatly reduce the use of raw materials, and make the product lighter, so that the wall dry hanging load is also light, and the dry hanging safety is higher. It should be noted that when the concave or convex surface of the front surface of the concave-convex ceramic plate material is used as the back surface of the product, the back surface of the concave-convex ceramic plate material is used as the front surface of the product, and the front surface of the product does not need to form a decorative effect layer.

[0042] Optionally, the surface of the concave-convex ceramic plate material is bright, brushed, matte dry grain, or matte glaze, etc.

[0043] Optionally, the volume density of the flat area, convex area, or concave area of the concave-convex ceramic plate material reaches 2.4±0.1 g / cm 3 It should be noted that the front surface of the concave-convex ceramic plate material has a convex area or a concave area, and the area of the front surface other than the convex area or the concave area is the flat area.

[0044] Optionally, the volume density of the flat area, convex area, or concave area of the concave-convex ceramic plate material reaches 2.35±0.05 g / cm 3 .

[0045] The present invention has the following advantageous effects:

[0046] First, the invention provides a positive hitting type integrated dry pressing forming concave-convex ceramic plate and its manufacturing method, which innovatively uses pre-layout raw material modeling to match the predetermined modeling mold of the press to manufacture the integrated forming of the large area concave-convex shaped plate, solving the consistency and uniformity problem of the green body raw material when being pressed. Compared with the conventional matching of the overall flat layout material and the modeling mold, it breaks through the limitation that the powder in the range of more than 30mm wide and 100mm long of the concave-convex surface of the modeling mold cannot flow and the manufacturing of the large area concave-convex plate is difficult to achieve. The pre-molding layout material of the invention can be well matched with the molding mold, so that the overall powder can be uniformly stressed during the pressing process, and the green body after pressing is dense and uniform, and the pressing force of the press is in the range of 220bar-250bar, without specific pressing. After firing, the volume density of the main flat area and the raised area or the recessed area of the plate reaches 2.4±0.1g / cm 3 or even 2.35±0.05g / cm 3 , with high strength, good bending resistance, good integration and other characteristics, so that the product quality is more stable, solving the quality problems such as delamination, deformation, cracking and breaking of the existing technology for manufacturing concave-convex ceramic plate.

[0047] Second, the invention provides a positive hitting type integrated dry pressing forming concave-convex ceramic plate and its manufacturing method, which can design the predetermined main shape and the concave-convex modeling of the area according to the needs, for example, the raised edge around the plate can prevent water from overflowing outside the table surface in the predetermined table surface application of kitchen and bathroom, tea set, etc., and the predetermined concave or convex modeling area on the main flat surface of the plate can be used to place predetermined objects, with aesthetic and practicality. The above design not only achieves the effect of combining practicality and decoration, but also provides designers and users with personalized and differentiated product material selection; second, the manufacturing method can be pressed and formed at one time, which not only successfully realizes the standardized mass production of the shaped ceramic plate, but also reduces the secondary processing of the ceramic plate during use, avoids the problems of cracking, damage, cutting waste and sewage discharge during splicing processing, and saves the cost of labor, water and electricity, machine investment and maintenance, etc., achieving the purpose of energy saving, emission reduction, consumption reduction and environmental protection.

[0048] Third, the invention provides a positive hitting type integrated dry pressing forming concave-convex ceramic plate and its manufacturing method, which has the characteristics of the concave-convex shaped ceramic plate of the invention, and can also combine glaze, dry particles and inkjet technology of conventional ceramic process on the surface to achieve more rich decorative effect for consumers' diverse aesthetic selection. BRIEF DESCRIPTION OF DRAWINGS

[0049] Figure 1Stereoscopic design drawing of the product and the mold of the present application;

[0050] Figure 2 Schematic cross-sectional view of the press-formed body and the matched mold of the present application (the body is surrounded by convex surface area);

[0051] Figure 3 Schematic cross-sectional view of the press-formed body and the matched mold of the present application (the body is surrounded by concave surface area);

[0052] Figure 4 Front view of the lower plane of the upper mold according to embodiment 1 of the present application;

[0053] Figure 5 Front view of the body of the ceramic plate pressed according to the linear expansion rate of about 0.5% according to embodiment 1 of the present application;

[0054] Figure 6 Front view of the ceramic plate product according to embodiments 1, 5 and 7 of the present application;

[0055] Figure 7 Schematic cross-sectional view of the ceramic plate product according to embodiment 1 of the present application; Figure 6

[0056] Back view of the ceramic plate product according to embodiment 1 of the present application with 1 mm deep bottom line; Figure 8

[0057] Schematic cross-sectional view of the ceramic plate product according to embodiment 1 of the present application; Figure 9 Figure 8 Schematic cross-sectional view of the ceramic plate product according to embodiment 1 of the present application;

[0058] Figure 10 Figure 9 Schematic cross-sectional view of the ceramic plate product according to embodiment 1 of the present application;

[0059] Figure 11 Front view of the ceramic plate product according to embodiment 8 of the present application;

[0060] Figure 12 Front view of the ceramic plate product according to embodiment 2 of the present application;

[0061] Figure 13 Front view of the ceramic plate product according to embodiment 3 of the present application;

[0062] Figure 14 Front view of the ceramic plate product according to embodiment 8 of the present application;

[0063] Figure 15 Schematic cross-sectional view of the ceramic plate product according to embodiment 8 of the present application; Figure 14

[0064] Schematic cross-sectional view of the ceramic plate product according to embodiment 8 of the present application; Figure 16 ​​​

[0065] Figure 17 Front view of ceramic plate product made in Example 9 of the present application;

[0066] Figure 18 Sectional view of P-P part in Figure 17

[0067] Figure 19 Perspective view of ceramic plate product made in Example 9 of the present application;

[0068] Figure 20 Back view of ceramic plate product made in Example 10 of the present application;

[0069] Figure 21 Sectional view of K-K part in Figure 20

[0070] Figure 22 Enlarged view of I part in Figure 21

[0071] Figure 23 Cloth state diagram of Example 1 of the present application;

[0072] Figure 24 Perspective view of hopper N in Figure 23

[0073] Figure 25 Cloth state diagram of hopper N in which cloth is spread to form a peripheral raised surface area; Figure 23

[0074] Figure 26 Cloth state diagram of hopper M in which cloth is spread to form a main flat blank layer; Figure 23

[0075] Figure 27 Figure 25 26 Overall cloth state diagram in which the cloth states are superimposed;

[0076] Figure 28 Volume density comparison diagram of main flat surface area and raised area of ceramic plate product made by using a press with a pressure of 230 bar in Example of the present application;

[0077] Figure 29 Volume density comparison diagram of main flat surface area and raised area of product made by using a press with a pressure of 230 bar in Comparative Example;

[0078] Figure 30 Volume density comparison diagram of main flat surface area and raised area of product made by using a press with a pressure of 310 bar in Comparative Example. ​​​​​​​​

[0079] Explanation of reference numerals in the drawings

[0080] M represents a main material distribution hopper (for distributing a main body flat blank layer), N represents a predetermined belt type material distribution hopper at the front end (extending end) of the material distribution grid (for distributing a raised area), and a represents the included angle of the connecting edge of the main body flat surface and the raised (depressed) surface area flat surface with the vertical direction. DETAILED DESCRIPTION

[0081] The present application provides a concave-convex ceramic plate formed by positive punching and integrated dry pressing and a manufacturing method thereof. To make the purpose, technical scheme and effects of the present application more clear and explicit, the present application is further described in detail below. It should be understood that the specific embodiments described herein are only used to explain the present application and not to limit the present application.

[0082] Example 1

[0083] Taking a quadrilateral ceramic plate with a length of 1500 mm, a width of 800 mm, a thickness of 25 mm (the thickness of the flat surface area on the front surface is 20 mm, and the thickness of the raised surface area around the periphery is 5 mm), a width of the raised surface area around the periphery of 100 mm, and an included angle a of the side connecting the flat surface area and the raised surface area around the periphery with the vertical direction of 73°, and a grid-shaped flat bottom line with a depth of 1 mm on the back surface (see FIG. 1) as an example, the specific process is as follows. Figures 8-11

[0084] (1) Mould design: the upper and lower moulds with the predetermined shape required for pressing are prepared according to the design and installed on the ceramic press of the production line; wherein the moulds prepared are as follows:

[0085] The upper mould with a length of 1670 mm and a width of 905 mm is designed and prepared according to the predetermined shape of the surface of the ceramic plate to be prepared (see FIG. 2), and is matched with the lower mould with the same size and a grid-shaped flat bottom line with a depth of 1 mm on the upper surface; Figure 4

[0086] It should be noted that the four peripheral depressed edges in the upper mould are not limited to four depressed edges, and any design with 1-4 edges can be used according to the requirement, and the edge width parameter can be designed and prepared according to the requirement, and the four edges can be equal or unequal (four depressed edge design is adopted in this embodiment).

[0087] (2) Raw material preparation:

[0088] ① Preparation of a blank material, the water content of the blank material is 8%, and the particle size of the blank material is 85% or more than 85% through a 60 mesh screen;

[0089] ② Preparation of a glaze, the specific gravity of the glaze is 1.85 g / cm 3 ​​, the flow rate is 45 s; wherein, the specific gravity is adjusted to 1.18 g / cm 3 as a standby glaze 1; the flow rate is adjusted to 35 s as a standby glaze 2;

[0090] (3) Machine preparation: as shown in Figures 23-24 , a specific designed mechanical secondary distribution mechanism connected with the ceramic press is designed and installed, the time related parameters of the valve opening and closing (opening is equal to discharging, closing is equal to no discharging) of the main distribution hopper M and the predetermined belt type distribution hopper N at the front end (extension end) of the distribution grid are set, and the green body material prepared in step (2) ① is sent into the main distribution hopper M and the belt type distribution hopper N of the distribution mechanism;

[0091] (4) Distribution: as shown in Figures 25-27 , the main distribution hopper M distributes the green body material in the hopper into the distribution grid, and the green body material is framed by the distribution grid to form an overall planar layout in the press mold cavity in a one-time distribution manner, then the mold is lowered for the first time, and then the grid performs secondary distribution on the powder in the distribution hopper (valve controlled predetermined opening and closing) on the planar layout material in the mold cavity according to the modeling of the upper mold through the rotation of the belt of the predetermined belt type distribution hopper N in front of the grid during the returning process, to obtain the superposition of the powder with a predetermined thickness and width on the four peripheral edges of the planar layout material, so that the powder in the mold cavity corresponds to the overall preliminary modeling layout with a thickness difference between the four peripheral protruding surface domains and the planar area according to the predetermined modeling of the upper mold.

[0092] (5) Pressing: first, the press adopts a pressure of 230 bar to press the preliminarily modeled layout material through the predetermined mold to form a green body with a length of 1678 mm and a width of 910 mm (the linear expansion rate of the green body after pressing is about 0.5%), as shown in Figure 5 , then the green body is ejected from the mold cavity by the 1 mm deep grid-shaped back texture type lower mold, and is pushed out of the press by the moving belt front push brick rod, while the distribution grid returns to the distribution mechanism below to continue the next round of operation;

[0093] (6) Drying: the formed green body is dried, wherein the drying kiln temperature is 180℃, and the drying time is 75 minutes, and the water content of the green body after drying is less than 0.3%;

[0094] (7) Glazing: the standby glaze 1 in step (2) ② is sprayed on the surface of the dried green body, wherein the spraying amount is 200 g / m 2 ; then the standby glaze 2 in step (2) ② is sprayed, wherein the spraying amount is 650 g / m 2, so as to form a surface decoration layer; (since the green body surface has two thickness layer structures, in order to avoid the glaze to be accumulated or applied unevenly at the joint of the two thickness layers, twice glazing is preferably adopted, i.e. a layer of low specific gravity glaze is first sprayed to form a transition layer, and then a layer of glaze is sprayed, so that the applied glaze is more evenly distributed, the surface is more flat, and the quality is more stable.)

[0095] (8) Firing: firing in a kiln with a maximum temperature of 1140-1220°C for 70 minutes to obtain a semi-finished product;

[0096] (9) Processing: cooling, edge grinding; combination Figures 6-7 As shown in FIG. 1, by converting about 9% of the firing shrinkage and about 2% of the edge grinding cutting rate, a concave-convex ceramic plate with a length of 1500 mm, a width of 800 mm, a length of the planar area of 1268 mm, a width of the planar area of 568 mm, a thickness of the planar area of 20 mm, a thickness of the convex area around the planar area of 5 mm, a distance between the side of the planar area closest to the convex area and the vertical direction of 16 mm, an angle a between the side of the planar area and the vertical direction of 73°, and a width of the convex area of 100 mm is obtained; the volume densities of the planar area and the convex area of the concave-convex ceramic plate reach 2.35±0.05 g / cm 3 , as shown in FIG. 1. Figure 28

[0097] Example 2

[0098] On the basis of Example 1, a small convex strip is further arranged on the middle convex plane of the lower surface of the upper mold of the press; i.e. a concave-convex ceramic plate with a draining groove on the planar area is obtained, as shown in FIG. 2. Figure 12

[0099] Example 3

[0100] On the basis of Examples 1 and 2, a convex plane is further arranged on the middle convex plane of the lower surface of the upper mold of the press; i.e. a concave-convex ceramic plate with a draining groove on one side of the planar area and a concave area on the other side of the planar area is obtained, as shown in FIG. 3. Figure 13

[0101] Example 4

[0102] On the basis of Examples 1, 2 and 3, the composition of the green body material in this example is a mixture of a powder with a sieve residue of more than 85% through a 60-mesh sieve and particles with a predetermined gradation and color; i.e. the concave-convex ceramic plate with particle effects in the green body is obtained.

[0103] Example 5

[0104] ​​​On the basis of embodiment 1, this embodiment uses a mechanical and digital controlled digital cloth mechanism to replace steps (3) and (4) of embodiment 1. First, the digital cloth mechanism connected with the ceramic press is installed. The cloth mechanism is provided with four cloth channels: T1, T2, T3 and T4. T1 and T2 are used for cloth laying of the overall plane, T3 is used for cloth laying of the four around raised edges, and T4 is used for thickness compensation. The cloth pattern file matched with the molding of the press mold is set in advance and input into the computer of the digital cloth mechanism. The digital cloth mechanism is started. Through the matching of the parameters set in the pattern file, the cloth valves of T1 and T2 are fully opened, the cloth key of the cloth mechanism is started, the T1 belt lays the material of No. 1 belt on the overall plane, when the material of No. 1 belt reaches the laying position of T2, the T2 belt is started, the material of T2 is stacked on the surface of the material of T1, forming the overall plane layout material. When the material of No. 1 belt reaches the laying position of T3, the T3 belt is started (the cloth valve of T3 is opened and closed according to the pattern file, opening is equal to laying, and closing is equal to not laying), the material of T3 belt is stacked on the four around edges of the material of the previous two channels, forming the predetermined cloth thickness difference. When the material of No. 1 belt reaches the laying position of T4, the T4 belt is started, the material of T4 is stacked on the surface of the material of the previous three channels, forming the predetermined preliminary molding layout. The material of T1-T4 is carried on the No. 2 belt by the No. 1 belt, and the thickness is accumulated on the No. 2 belt (through the speed difference between the No. 2 belt and the No. 1 belt, that is, the rotating speed of the No. 2 belt is slower than that of the No. 1 belt). After the No. 2 belt receives the material, the material is transferred to the No. 3 belt (the speed of the No. 2 belt and the No. 3 belt is synchronized), then the No. 3 belt sends the material forming the preliminary molding layout matched with the molding mold of the press into the mold cavity of the press (the thickness of the powder in the mold cavity of the press and the width of the four around raised edges are basically the same as those of the No. 3 belt), then the press uses a pressure of 230 bar to press the powder forming the preliminary layout molding into a green body from the front (the brick molding surface faces upward). The green body is pushed out of the mold cavity by the back texture plane lower mold with a depth of 1 mm, and then pushed out of the press by the pushing brick rod in front of the No. 3 moving belt. After the subsequent processes, a concave-convex ceramic plate with a length of 1500 mm, a width of 800 mm, a length of the plane area of 1268 mm, a width of 568 mm, a thickness of 20 mm, a thickness of the four around raised area of 5 mm, a distance between the adjacent side edges of the plane area and the four around raised area of 16 mm, an angle a between the side edge of the plane area and the four around raised area and the vertical direction of 73°, and a width of the four around raised area of 100 mm is obtained. The No. 3 moving belt returns to the cloth mechanism to continue the next operation, as shown in Figure 6 、 7 、11.

[0105] Embodiment 6

[0106] On the basis of Embodiment 5, this embodiment uses either the powder with more than 85% of the amount of residue passing through a 60-mesh screen or the mixture of the powder with more than 85% of the amount of residue passing through a 60-mesh screen and the particles with predetermined gradation and color as the main material, and additionally uses the powder with a color different from that of the main material as the line material or / and the color zone material, so that the predetermined color zone or / and line material is applied simultaneously in the process of flat laying by the predetermined belt in the mechanical and digitally controlled digital material laying mechanism, thereby producing the concave-convex ceramic plate material with the color zone or / and line effect in the body.

[0107] Embodiment 7

[0108] Unlike Embodiment 1, this embodiment uses a conventional one-time material laying mechanism (or a mechanical and digitally controlled digital material laying mechanism) to apply the powder directly into the mold cavity of the press by the grid or moving belt of the material laying mechanism to form an overall flat layout in step (4), and then scrapes the material according to the predetermined modeling of the mold by the predetermined scraping device. The process parameters of the scraping device are set, in which the width of the four raised edges (not scraped) is reserved, the middle predetermined width of the scraper of the scraping device (consistent with the width to be scraped, i.e., minus the width of the four raised edges) and the length of the downward extension (the length matches the thickness to be scraped) are set, and the parameters such as the time and position of the descent and ascent of the scraper are set. After the scraper scrapes the thickness of the powder on the upper layer of the middle part (predetermined position) of the overall powder in the mold cavity by the rotation of the impeller thereon or sucks it up by the vacuum negative pressure, the middle recessed part with a predetermined thickness of the powder is obtained, so that the powder in the mold cavity forms an overall preliminary modeling layout with a thickness difference between the middle recessed part and the four raised edges according to the modeling of the upper mold. The scraped powder is guided to the recycling hopper by the built-in belt of the scraping device for repeated use.

[0109] After the powder in the mold cavity forms the preliminary layout modeling, the body is pressed by the press with a pressure of 230 bar to form a body, and the body is ejected from the mold cavity by the 1-mm-deep grid-shaped back-textured flat lower mold and pushed out of the press by the push brick rod in front of the material laying grid or moving belt, and then subjected to subsequent processes to produce a concave-convex ceramic plate material with a length of 1500 mm, a width of 800 mm, a length of the flat area of 1268 mm, a width of 568 mm, a thickness of 20 mm, a thickness of the four raised areas of 5 mm, a distance between the side edges of the flat area and the four raised area of 16 mm, an angle a between the side edge of the flat area and the four raised area and the vertical direction of 73°, and a width of the four raised area of 100 mm. The material laying grid or moving belt returns to the material laying mechanism to continue the next round of operation, as shown in Figure 6 、 7 、11.

[0110] Embodiment 8

[0111] The difference between this embodiment and the above embodiments is that this embodiment takes the production of a circular ceramic plate with a diameter of 1000 mm and a maximum thickness of 30 mm as an example, the circumference of which is provided with a raised edge with a thickness of 10 mm and a width of 160 mm, and the connecting edge between the planar surface area and the planar surface area of the circumferential raised area has an angle a of 10° with the vertical direction, as shown in Figures 14-16 The corresponding matching molding mold is designed in reverse according to the above-mentioned desired plate production, and the powder is laid out in a predetermined manner by any one of the laying mechanisms described in the above embodiments, and the powder forming the initial layout model is pressed into a green body by the press at a pressure of 230 bar, and the green body is pushed out of the press by the pushing brick rod in front of the laying grid or the moving belt after being pushed out of the mold cavity by the 1 mm deep grid-shaped back texture lower mold, and then the concave-convex ceramic plate with a diameter of 1000 mm, a planar surface area thickness of 20 mm, and a circumferential raised surface area thickness of 10 mm, a width of 160 mm, and a connecting edge between the planar surface area and the planar surface area of the circumferential raised area having an angle a of 10° with the vertical direction is obtained after the subsequent processes, as shown in Figures 14-16 .

[0112] Embodiment 9

[0113] The difference between the present embodiment and the above embodiments is that the present embodiment takes the production of a rhombic ceramic plate with a side length of 1000 mm and a maximum thickness of 30 mm as an example, and a triangular convex surface area with a thickness of 10 mm and a diagonal side length of 190 mm and 240 mm near the center edge of the plate is arranged on each of the four corners of the rhombic ceramic plate, and the connecting edge of the planar surface area and the triangular convex surface area is perpendicular to the vertical direction (i.e., the connecting edge of the triangular convex surface area and the planar surface area is perpendicular to the triangular convex surface area and the planar surface area). The above-mentioned required plate is reversely designed to obtain a corresponding matching molding mold, and the powder is arranged in a predetermined manner by any one of the above-mentioned material arrangement mechanisms, and the powder arranged in the preliminary layout is pressed into a green body by the press at a pressure of 230 bar. The green body is pushed out of the press by the pushing brick rod in front of the material grid or the moving belt after being pushed out of the mold cavity by the 1 mm deep grid-shaped back texture plane lower mold, and then the concave-convex ceramic plate with a side length of 1000 mm, a planar surface area thickness of 20 mm, and a triangular convex surface area with a thickness of 10 mm and a diagonal side length of 190 mm and 240 mm near the center edge of the plate on each of the four corners is obtained after the subsequent processes, as shown in FIG. 10. Figures 17-19

[0114] Embodiment 10

[0115] In combination Figures 20-23 ​The difference between the embodiment and the above-mentioned embodiments is that the depth of the bottom texture of the lower surface of the upper mold is different. In the embodiment, the raised areas on the lower surface of the upper mold are uniformly provided with small protrusions with a height of 1 mm corresponding to the upper flat areas of the lower mold, and the recessed areas on the lower surface of the upper mold are uniformly provided with small protrusions with a height of 3 mm corresponding to the upper flat areas of the lower mold. The depth of the recessed texture formed by the small protrusions uniformly distributed on the upper flat surface of the lower mold is at the same level, and the edges of the small protrusions form an 11° inclined surface with the vertical direction, so that the depth of the recessed texture on the back surface of the plate corresponding to the position of the raised area on the front surface of the plate is 1 mm, and the depth of the recessed texture on the back surface of the plate corresponding to the position of the raised area on the front surface of the plate is 3 mm. The edges of these uniformly distributed recessed textures form a protrusion texture at the same level with an 11° inclined surface with the vertical direction, and the recessed texture and the protrusion texture together form the overall back surface texture of the plate. The recessed depth of the plate back surface texture is designed according to the corresponding area of the plate front surface recessed and raised area, and the position with a recessed depth of 3 mm corresponds to the raised area on the front surface of the plate, and the position with a recessed depth of 1 mm corresponds to the recessed area on the front surface of the plate. Through such design, the difference between the overall thickness of the blank can be further reduced, and a certain compensatory balance can be obtained, so as to further improve the consistency of oxidation exhaust and drainage and sintering property of the blank during firing, and the design of the protrusion texture at the same level is to make the blank bottom surface after demolding flatly run on the transmission line.

[0116] Example 11

[0117] On the basis of the above-mentioned embodiments, pre-designed pattern inkjet printing is carried out before or after step (7) to form a superimposed decorative effect.

[0118] Example 12

[0119] On the basis of the above-mentioned embodiments, in step (7), only one layer of transparent protective glaze is applied.

[0120] Comparative Example

[0121] The same as example 1, except that the pre-designed upper mold is used to press the overall flat-shaped powder, and the powder in the range of more than 30 mm wide and 100 mm long of the concave and convex surface of the molding mold cannot flow, so the thickness of the powder layout in the mold cavity of the press is basically the same, and the contact range of the protrusion part of the mold with the overall flat material is relatively dense, while the contact range of the concave part of the mold with the overall flat material is relatively low in density, thereby forming a large difference in density. In the demolding process after pressing, the protrusion part of the blank corresponding to the concave part of the mold is prone to delamination due to insufficient density of the raw material, and the uneven density leads to inconsistent drainage and oxidation exhaust during firing.Figure 29 As shown, the press adopts 230 bar pressure, and the volume density of the flat area of the fired plate is 2.4 g / cm 3 , and the volume density of the convex area is only 2.0 g / cm 3 . The volume densities of the two areas are too different, which leads to a series of problems such as large deformation of the fired plate, easy cracking and delamination at the contact between the flat area and the convex area, even breaking of the whole plate, and color difference between the flat area and the convex area. Figure 30 As shown, if the press is pressurized and the pressure is more than 300 bar, the volume density of the flat area of the fired plate is 2.6 g / cm 3 , and the volume density of the convex area is 2.2 g / cm 3 . Although the volume density of the convex area is increased by pressurization, the volume density of the flat area is also increased accordingly, and the volume densities of the two areas are still too different. The uneven volume density of the whole plate also leads to a series of quality problems.

[0122] The embodiment of the application innovatively adopts the method of pre-arranging the shape of raw materials to match the upper mold of the predetermined shape of the press. The arrangement of the powder has preliminarily formed a preliminary shape corresponding to the upper mold of the press before being pressed, which can keep the consistency and uniformity of the whole raw material during pressing, and the compactness of the pressed body is uniform. The press adopts a pressure range of 220 bar to 250 bar, and does not need special pressurization. The volume densities of the flat area and the convex area of the fired plate are both 2.4±0.1 g / cm 3 , or even 2.35±0.05 g / cm 3 . The volume density is consistent as a whole, and has the characteristics of high strength, good folding resistance, and good integrity, so that the product quality is more stable.

[0123] From the above comparison, if the compactness of the pressed body is not uniform, the drainage, oxidation exhaust, and glaze layer affected by the exhaust are not consistent during the firing process, which leads to a series of problems such as large deformation of the fired plate, easy cracking at the contact between the flat area and the convex area, even breaking of the whole plate, and color difference between the flat area and the convex area. Moreover, the pressure of the press is not the larger the better. If a larger pressure is used for pressing for a long time, the damage to the machine will also be increased. The most critical point is that no matter how large the pressure of the press is, if the volume shape of the raw material in the mold cavity and the mold shape cannot be matched, the volume density of the fired body as a whole will not be consistent. Therefore, to solve these problems, the shape of the raw material is directly arranged in advance to match the shape of the mold, so that the whole raw material is uniformly pressed, the compactness of the body is uniform, the oxidation exhaust during the firing process is beneficial, the whole is consistent and sufficient, the sintering is good, the glaze layer is also controlled, and the surface color difference problem is solved.

[0124] It is to be understood that the application is not limited to the examples described above, which can be modified or adapted in several ways by those skilled in the art without departing from the scope of the present application, as defined by the appended claims.

Claims

1. A method for manufacturing a concave-convex ceramic plate material by positive dry press forming, characterized by, The method comprises the following steps: Preparation of raw materials required for making the concave-convex ceramic plate; According to the predetermined shape of the front and back surfaces of the concave-convex ceramic plate, a mold is designed reversely, wherein the lower surface of the upper mold is a concave-convex shaped surface, which is designed to be a male or female counterpart of the concave-convex shaped surface of the concave-convex ceramic plate; the size of the mold is designed by enlarging the size of the concave-convex ceramic plate by 1%-3% to meet the requirement of edge grinding and cutting, and then the size of the mold is designed according to the shrinkage rate of 8.5%-10.5% of the ceramic plate; A layout of raw materials with a predetermined shape corresponding to the shape of the upper mold is formed in the mold cavity of the press by using a material distribution mechanism, specifically including: forming a whole flat layout of raw materials in the mold cavity of the press by using the material distribution mechanism, and then forming a layout of raw materials with a predetermined shape corresponding to the shape of the upper mold by collecting and scraping the raw materials at a predetermined position through a collecting and scraping device; The layout of raw materials with a predetermined shape is pressed into a green body by using the press and the mold with a predetermined shape; The green body is dried; The dried green body is fired to obtain a semi-finished product; The semi-finished product is cooled and edge ground to obtain the concave-convex ceramic plate.

2. The method of claim 1, wherein the method further comprises the step of: The step of forming a layout of raw materials with a predetermined shape corresponding to the shape of the upper mold in the mold cavity of the press by using a material distribution mechanism specifically includes: ​ A layout of raw materials with a predetermined thickness is formed in the mold cavity of the press by using the material distribution mechanism, and then a layout of raw materials with a predetermined shape corresponding to the shape of the upper mold is formed by superimposed material distribution at a predetermined position; Alternatively, a layout of raw materials with a predetermined thickness is formed on a conveying belt by using the material distribution mechanism, and then a layout of raw materials with a predetermined shape corresponding to the shape of the upper mold is formed by superimposed material distribution at a predetermined position, and the layout of raw materials with a predetermined shape is sent into the mold cavity of the press.

3. A concave-convex ceramic plate material integrally dry-pressed by a positive punch, characterized by The front surface of the concave-convex ceramic plate has at least one concave surface or convex surface, the planar size of the concave surface or convex surface is greater than or equal to 30 mm in width and greater than or equal to 100 mm in length, and the minimum difference between the concave surface and the convex surface of the concave-convex ceramic plate is 3-10 mm; The side of the concave surface or convex surface of the front surface of the concave-convex ceramic plate has an angle of 0-75° with the vertical direction; the top of the convex surface and the bottom of the concave surface of the front surface of the concave-convex ceramic plate are respectively in the same plane or not in the same plane; and the vertical projection of any edge of each plane of the convex surface and the concave surface on the bottom plane of the plate does not coincide.

4. The positive striking one-piece dry-pressed concave-convex ceramic slab according to claim 3, characterized in that, The front surface of the concave-convex ceramic plate has at least one concave surface or convex surface, the planar size of the concave surface or convex surface is greater than or equal to 50 mm in width and greater than or equal to 100 mm in length, and the minimum difference between the concave surface and the convex surface of the concave-convex ceramic plate is 5-10 mm.

5. The positive striking one-piece dry-pressed concave-convex ceramic slab according to claim 3, characterized in that, The back surface of the concave-convex ceramic plate is further provided with a grid-shaped concave-convex texture composed of predetermined concave lines and surrounding convex lines, the concave depth of the concave lines on the back surface of the ceramic plate corresponding to the concave area on the front surface of the concave-convex ceramic plate is 0.5mm-1mm; the concave depth of the concave lines on the back surface of the concave-convex ceramic plate corresponding to the convex area on the front surface of the concave-convex ceramic plate is 2mm-3mm; the convex lines on the back surface of the concave-convex ceramic plate are in the same horizontal plane, and the edge of the convex lines is a slope surface with an angle greater than or equal to 10° with the vertical direction.

6. The positive striking one-piece dry-pressed concave-convex ceramic slab according to claim 3, characterized in that, The main body shape of the concave-convex ceramic plate is any one of a triangular shape, a quadrilateral shape, a circular shape, an elliptical shape, a diamond shape, a trapezoidal shape, and a polygonal shape. The shape of the concave surface or the convex surface on the front surface of the concave-convex ceramic plate is one or a combination of more than one of a triangular shape, a quadrilateral shape, a circular shape, an elliptical shape, a diamond shape, a trapezoidal shape, and a polygonal shape.

7. The positive striking one-piece dry-pressed concave-convex ceramic slab according to claim 3, characterized in that, The concave surface or the convex surface on the front surface of the concave-convex ceramic plate is further provided with a plurality of small grooves or small convex strips, the width of the small grooves or the small convex strips is 10mm-20mm, and the depth or the height is 3mm-10mm.

8. The positive striking one-piece dry-pressed concave-convex ceramic slab according to claim 3, characterized in that, The concave surface or the convex surface on the front surface of the concave-convex ceramic plate is further provided with small concave or small convex.

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