A kind of ceramic tile with realistic stone imitation effect and preparation method thereof

Abstract

The present invention belongs to the field of architectural ceramics technology and specifically discloses a realistic stone-like ceramic tile and a preparation method thereof. The stone-like ceramic tile comprises, from bottom to top, a lower body layer, an upper body layer, a top glaze layer, and a transparent glaze layer, wherein: the raw material components of the upper body layer contain diatomaceous earth, the top glaze layer and the transparent glaze layer are respectively formed by electrostatic spraying of the top glaze and the transparent glaze, and the glaze viscosity of the top glaze is 8-12 mPas. The stone-like ceramic tile of the present invention abandons the traditional glazing method and adopts electrostatic spraying for glazing. By adjusting the body glaze formula composition and preparation process, the glaze layer after sintering is thin and uniform. The prepared ceramic tile has a realistic stone-like effect and the glaze surface is free of defects such as orange peel and pinholes.

Description

Technical Field

[0001] The invention belongs to the technical field of building ceramics, and particularly relates to a realistic stone-imitation ceramic tile and a preparation method thereof. Background Art

[0002] Imitation stone ceramic tiles mimic the patterns, colors, textures, and shapes of natural stone. While inheriting the appearance of natural stone, they surpass it in many other aspects, including quality, texture, surface, specifications, and color. Compared to the radiation pollution of natural stone, imitation stone ceramic tiles are not only radioactive but also avoid the drawbacks of uneven color and intensity. Imitation stone ceramic tiles rival natural stone, surpassing its performance, offering healthier and greener qualities than stone. This is the perfect decorative material that the architectural design community has been pursuing in recent years.

[0003] Currently, most stone-like ceramic tiles on the market are top-glazed by pouring glaze onto a regular base, then inkjet-printing a stone-like pattern, and finally applying a clear glaze. However, due to the uneven texture of stone-like ceramic tiles, pouring glaze can cause the glaze to flow from raised areas into recessed areas due to its fluidity. This results in a thicker glaze layer in these recessed areas than on the raised areas, leading to uneven glaze thickness across different areas, significantly reducing the stone-like effect.

[0004] Therefore, it is urgent to develop a stone-like ceramic tile that has a realistic stone-like three-dimensional effect with a uniform glaze layer thickness without affecting the overall performance and glaze quality of the tile. Summary of the Invention

[0005] The present invention aims to address at least one of the technical problems existing in the aforementioned prior art. To this end, the present invention provides a realistic stone-like ceramic tile and a method for preparing the same. This invention abandons existing glazing techniques and instead employs electrostatic spraying. By adjusting the composition and preparation process of the base glaze, the sintered glaze layer is thin and uniform, resulting in a high-quality glaze surface. The resulting ceramic tile exhibits a realistic stone-like effect.

[0006] In order to solve the above technical problems, the first aspect of the present invention provides a stone-like ceramic tile, which includes, from bottom to top, a lower body layer, an upper body layer, a surface glaze layer and a transparent glaze layer; the raw material components of the upper body layer contain diatomaceous earth, and the surface glaze layer and the transparent glaze layer are respectively formed by electrostatic spraying of the surface glaze and the transparent glaze; the glaze viscosity of the surface glaze is 8-12mPas.

[0007] Specifically, the ceramic tile of the present invention is applied with a surface glaze and a transparent glaze by electrostatic spraying to form a surface glaze layer and a transparent glaze layer. The principle of electrostatic spraying is to apply 60,000-80,000V high-voltage static electricity on the glaze. Once the glaze leaves the spray gun during the glazing process, these particles carry a high-voltage positive charge, and there is a considerable unidirectional mutual repulsion between the particles, thereby causing the glaze particles to produce an extremely uniform atomization effect. At the same time, since the glaze and the blank are always in a high-voltage electrostatic field, the surface of the blank carries a strong negative charge. Under the action of the electric field, the positively charged glaze is adsorbed by the negative charge on the surface of the blank, forming an extremely dense and uniform glaze layer. However, the electrostatic spraying technology uses centrifugal atomization to atomize the electrostatic glaze water into fine and uniform mist slurry particles. During the electrostatic adsorption process, the temperature of the brick surface causes the water in the glaze water particles close to each other to evaporate, forming a dry powder particle glaze surface, which reduces the adsorption force between the blank and the glaze, and causes the glaze surface to produce glaze defects such as peeling and corrugation. On the one hand, the present invention adds a certain amount of diatomaceous earth to the upper body layer so that the diatomaceous earth is mainly distributed on the upper surface of the body layer, and utilizes the fine porous structure characteristics of the diatomaceous earth to improve the adsorption force of the upper body layer to the electrostatic glaze without reducing the strength of the body; on the other hand, by adjusting the formula composition of the surface glaze layer, the glaze viscosity of the surface glaze is adjusted to 8-12mPas, so that the glaze has good fluidity, thereby improving the uniformity of the glaze atomization. The two work together to effectively improve the quality of the glaze surface and make it smoother and more delicate.

[0008] As a further improvement of the above scheme, the raw material components of the glaze include, by weight: 30-45 parts of quartz, 20-25 parts of feldspar, 10-15 parts of aluminum oxide, 8-13 parts of calcium carbonate, 1-4 parts of calcined talc, 3-5 parts of zinc oxide, 1-3 parts of zirconium silicate, 0.5-1 part of sodium carboxymethyl cellulose, and 8-12 parts of cobalt black material.

[0009] Specifically, during the electrostatic glaze spraying process, the electrostatic glaze water is atomized into fine, uniform mist slurry particles, forming a dry powder particle glaze surface on the brick surface. When the glaze viscosity is high, the powder glaze surface is prone to defects such as orange peel and pinholes after sintering. The present invention adjusts the formula composition of the top glaze, controls the silicon-aluminum ratio, and adds a certain amount of sodium carboxymethyl cellulose and feldspar to reduce the glaze viscosity, thereby increasing the glaze fluidity and improving the glaze surface quality.

[0010] As a further improvement of the above solution, the raw material components of the lower green body layer include, by weight: 30-60 parts of clay, 10-25 parts of feldspar, 20-35 parts of quartz, 2-5 parts of talc, 3-8 parts of bauxite, 0.1-0.3 parts of sodium carboxymethyl cellulose, 0.2-0.3 parts of sodium tripolyphosphate, and 0.3-0.7 parts of polyacrylamide.

[0011] As a further improvement to the above solution, the raw material composition of the upper body layer is based on the raw material composition of the upper body layer and 8-15 wt% of diatomaceous earth is added. That is, the raw material composition of the upper body layer is: based on 100 total weight parts of the raw material of the lower body layer, 8-15 weight parts of diatomaceous earth are added.

[0012] As a further improvement of the above solution, the thickness ratio of the upper green body layer to the lower green body layer is (1-3):(7-9).

[0013] Specifically, the green body layer of the present invention is arranged in two layers, an upper green body layer and a lower green body layer, wherein the upper green body layer contains a certain amount of diatomaceous earth to improve the adsorption effect between the green body layer and the surface glaze layer; at the same time, the raw material components of the upper green body layer only increase diatomaceous earth relative to the lower green body, and the upper green body layer is thinner than the lower green body layer. On the one hand, it can ensure that the diatomaceous earth is mainly on the upper surface of the green body, thereby improving the electrostatic adsorption between the green body and the glaze layer; on the other hand, the raw materials of the upper and lower green body layers are similar, which can effectively reduce the stratification phenomenon between the green bodies and improve the mechanical properties of the product.

[0014] As a further improvement of the above solution, the particle size of the surface glaze and the transparent glaze are both 5-10 μm.

[0015] Specifically, electrostatic glaze spraying requires not only a lower viscosity of the glaze, but also a smaller particle size. By controlling the particle size of the top glaze and the transparent glaze within an appropriate range, it is more conducive to the smoothness and delicacy of the glaze surface.

[0016] Preferably, the transparent glaze can be ordinary matte transparent glaze.

[0017] A second aspect of the present invention provides a method for preparing a stone-like ceramic tile. The method is used to prepare the stone-like ceramic tile, comprising the following steps:

[0018] (1) The raw materials for preparing the upper green body layer and the lower green body layer are respectively made into powders, and are pressed into shape using a stone-like mold with a concave-convex texture to obtain the green body layer;

[0019] (2) spraying a top glaze and a transparent glaze in sequence on the upper surface of the green body layer by electrostatic spraying to form a top glaze layer and a transparent glaze layer to obtain a semi-finished product;

[0020] (3) The semi-finished product is put into a kiln for firing to obtain the stone-like ceramic tile.

[0021] As a further improvement of the above solution, in step (2), the glaze amount of the top glaze is 70-100g / m 2 The amount of transparent glaze applied is 50-70g / m 2 .

[0022] As a further improvement to the above scheme, in step (2), the atomization pressure of the electrostatic glaze spraying is 0.3-0.5 MPa. Properly increasing the atomization pressure is conducive to maintaining the uniformity of the glaze layer thickness. If the atomization pressure is too high, the powder feeding part is easily worn, and if the atomization pressure is too low, the powder feeding part is easily blocked.

[0023] As a further improvement of the above scheme, in step (3), the calcination temperature is 1150-1220°C.

[0024] Compared with the prior art, the above technical solution of the present invention has at least the following technical effects or advantages:

[0025] The stone-like ceramic tiles of the present invention abandon the traditional glazing method and adopt electrostatic glaze spraying for glazing. By adjusting the formula composition and preparation process of the glaze, the glaze layer after sintering is made thin and uniform. The prepared ceramic tiles have a realistic stone-like effect and the glaze surface is free of defects such as orange peel and pinholes. At the same time, the body layer of the ceramic tiles of the present invention is arranged into an upper body layer and a lower body layer, and diatomaceous earth with good electrostatic adsorption properties is added to the upper body layer. While not reducing the strength of the body, the adsorption capacity of the body layer to the electrostatic glaze is increased, thereby improving the quality of the glaze surface. In addition, by adjusting the formula composition of the glaze surface, the glaze viscosity of the surface glaze is controlled within a certain range, thereby improving the uniformity of the glaze atomization, thereby further improving the quality of the glaze surface and making it smoother and more delicate. DETAILED DESCRIPTION

[0026] The present invention is described in detail below with reference to the examples to facilitate understanding of the present invention by those skilled in the art. It is necessary to point out that the examples are only used to further illustrate the present invention and are not to be construed as limiting the scope of protection of the present invention. Non-essential improvements and adjustments made to the present invention by those skilled in the art based on the above-mentioned invention should still fall within the scope of protection of the present invention. At the same time, the raw materials mentioned below that are not described in detail are all commercially available products; the process steps or preparation methods that are not mentioned in detail are all process steps or preparation methods known to those skilled in the art.

[0027] The transparent glaze layers in the following examples and comparative examples all adopt matte transparent glaze.

[0028] Example 1

[0029] A stone-like ceramic tile comprises, from bottom to top, a body layer, a surface glaze layer and a transparent glaze layer, wherein the body layer comprises a lower body and an upper body, and the thickness ratio of the lower body layer to the upper body layer is 8:2.

[0030] The raw material components of the lower green body layer are as follows by weight: 45.3 parts of clay, 18.6 parts of feldspar, 24.5 parts of quartz, 4.7 parts of talc, 6 parts of bauxite, 0.15 parts of sodium carboxymethyl cellulose, 0.25 parts of sodium tripolyphosphate, and 0.5 parts of polyacrylamide.

[0031] The raw material components of the upper green body layer are as follows by weight: 45.3 parts of clay, 18.6 parts of feldspar, 24.5 parts of quartz, 4.7 parts of talc, 6 parts of bauxite, 0.1 parts of sodium carboxymethyl cellulose, 0.25 parts of sodium tripolyphosphate, 0.5 parts of polyacrylamide, and 8 parts of diatomaceous earth.

[0032] In parts by weight, the raw material components of the surface glaze layer are: 34.5 parts of quartz, 22.5 parts of feldspar, 13.8 parts of aluminum oxide, 10.6 parts of calcium carbonate, 2.4 parts of calcined talc, 3.7 parts of zinc oxide, 2.8 parts of zirconium silicate, 0.7 parts of sodium carboxymethyl cellulose, and 9 parts of cobalt black material.

[0033] A method for preparing stone-like ceramic tiles comprises the following steps:

[0034] (1) The raw materials of the upper and lower green bodies are weighed and wet-milled according to the ratio, and then spray granulated to obtain the upper green body layer powder and the lower green body layer powder; then, they are sequentially spread on the bottom of the press, pressed into shape using a stone-like mold with a concave-convex texture, and the surface powder is removed to obtain the green body layer;

[0035] (2) Weighing the raw materials of the top glaze layer and the transparent glaze layer according to the ratio and wet ball milling them to obtain the top glaze and the transparent glaze; the glaze viscosity of the top glaze is 9 mPas and the particle size is 8 μm;

[0036] (3) Using electrostatic spraying, the top glaze and the transparent glaze prepared in step (2) are sprayed on the upper surface of the green body layer prepared in step (1) to form a top glaze layer and a transparent glaze layer, thereby obtaining a semi-finished product; wherein: the spray gun pressure is 0.4 MPa, and the glaze amount of the top glaze is 70 g / m 2 The amount of transparent glaze is 50g / m 2 ;

[0037] (4) The semi-finished product obtained in step (3) was fired at 1190° C. for 55 minutes to obtain the stone-like ceramic tile of this embodiment.

[0038] Example 2

[0039] A stone-like ceramic tile comprises, from bottom to top, a body layer, a surface glaze layer and a transparent glaze layer, wherein the body layer comprises a lower body and an upper body, and the thickness ratio of the lower body layer to the upper body layer is 7:3.

[0040] The raw material components of the lower green body layer are as follows by weight: 50.8 parts of clay, 15.4 parts of feldspar, 25.6 parts of quartz, 2.8 parts of talc, 4.2 parts of bauxite, 0.25 parts of sodium carboxymethyl cellulose, 0.25 parts of sodium tripolyphosphate, and 0.7 parts of polyacrylamide.

[0041] In parts by weight, the raw material components of the upper green body layer are: 50.8 parts of clay, 15.4 parts of feldspar, 25.6 parts of quartz, 2.8 parts of talc, 4.2 parts of bauxite, 0.25 parts of sodium carboxymethyl cellulose, 0.25 parts of sodium tripolyphosphate, 0.7 parts of polyacrylamide, and 15 parts of diatomaceous earth.

[0042] In parts by weight, the raw material components of the surface glaze layer are: 41.8 parts of quartz, 21.5 parts of feldspar, 10.8 parts of aluminum oxide, 8.3 parts of calcium carbonate, 2.4 parts of calcined talc, 3.7 parts of zinc oxide, 1.8 parts of zirconium silicate, 0.7 parts of sodium carboxymethyl cellulose, and 9 parts of cobalt black material.

[0043] A method for preparing stone-like ceramic tiles comprises the following steps:

[0044] (1) The raw materials of the upper and lower green bodies are weighed and wet-milled according to the ratio, and then spray-granulated to obtain the upper green body layer powder and the lower green body layer powder; then, they are sequentially spread on the bottom of the press, pressed into shape using a stone-like mold with a concave-convex texture, and the surface powder is removed to obtain the green body layer;

[0045] (2) Weighing the raw materials of the top glaze layer and the transparent glaze layer according to the ratio and wet ball milling them to obtain the top glaze and the transparent glaze. The viscosity of the top glaze is 11 mPas and the particle size is 5 μm.

[0046] (3) Using electrostatic spraying, the top glaze and the transparent glaze prepared in step (2) are sprayed on the upper surface of the green body layer prepared in step (1) to form a top glaze layer and a transparent glaze layer, thereby obtaining a semi-finished product; wherein: the spray gun pressure is 0.3 MPa, and the glaze amount of the top glaze is 90 g / m 2 The amount of transparent glaze is 70g / m 2 ;

[0047] (4) The semi-finished product obtained in step (3) was fired at 1200° C. for 57 minutes to obtain the stone-like ceramic tile of this embodiment.

[0048] Example 3

[0049] A stone-like ceramic tile comprises, from bottom to top, a body layer, a surface glaze layer and a transparent glaze layer, wherein the body layer comprises a lower body and an upper body, and the thickness ratio of the lower body layer to the upper body layer is 8:2.

[0050] The raw material components of the lower green body layer are as follows by weight: 57.8 parts of clay, 12.6 parts of feldspar, 21.5 parts of quartz, 3.2 parts of talc, 4 parts of bauxite, 0.15 parts of sodium carboxymethyl cellulose, 0.25 parts of sodium tripolyphosphate, and 0.5 parts of polyacrylamide.

[0051] The raw material components of the upper green body layer are as follows by weight: 57.8 parts of clay, 12.6 parts of feldspar, 21.5 parts of quartz, 3.2 parts of talc, 4 parts of bauxite, 0.15 parts of sodium carboxymethyl cellulose, 0.25 parts of sodium tripolyphosphate, 0.5 parts of polyacrylamide, and 12 parts of diatomaceous earth.

[0052] In parts by weight, the raw material components of the surface glaze layer are: 37.5 parts of quartz, 20.6 parts of feldspar, 12.8 parts of aluminum oxide, 9.4 parts of calcium carbonate, 2.7 parts of calcined talc, 4.5 parts of zinc oxide, 2.8 parts of zirconium silicate, 0.7 parts of sodium carboxymethyl cellulose, and 9 parts of cobalt black material.

[0053] A method for preparing stone-like ceramic tiles comprises the following steps:

[0054] (1) The raw materials of the upper and lower green bodies are weighed and wet-milled according to the ratio, and then spray-granulated to obtain the upper green body layer powder and the lower green body layer powder; then, they are sequentially spread on the bottom of the press, pressed into shape using a stone-like mold with a concave-convex texture, and the surface powder is removed to obtain the green body layer;

[0055] (2) Weighing the raw materials of the top glaze layer and the transparent glaze layer according to the ratio and wet ball milling them to obtain the top glaze and the transparent glaze. The viscosity of the top glaze is 12 mPas and the particle size is 10 μm.

[0056] (3) Using electrostatic spraying, the top glaze and the transparent glaze prepared in step (2) are sprayed on the upper surface of the green body layer prepared in step (1) to form a top glaze layer and a transparent glaze layer to obtain a semi-finished product; wherein: the spray gun pressure is 0.5 MPa, the glaze amount of the top glaze is 70 g / m 2 The amount of transparent glaze is 50g / m 2 ;

[0057] (4) The semi-finished product obtained in step (3) was fired at 1180° C. for 60 minutes to obtain the stone-like ceramic tile of this embodiment.

[0058] Comparative Example 1

[0059] A stone-like ceramic tile comprises, from bottom to top, a body layer, a surface glaze layer and a transparent glaze layer.

[0060] The raw material components of the green body layer are as follows by weight: 45.3 parts of clay, 18.6 parts of feldspar, 24.5 parts of quartz, 4.7 parts of talc, 6 parts of bauxite, 0.15 parts of sodium carboxymethyl cellulose, 0.25 parts of sodium tripolyphosphate, and 0.5 parts of polyacrylamide.

[0061] In parts by weight, the raw material components of the surface glaze layer are: 34.5 parts of quartz, 22.5 parts of feldspar, 13.8 parts of aluminum oxide, 10.6 parts of calcium carbonate, 2.4 parts of calcined talc, 3.7 parts of zinc oxide, 2.8 parts of zirconium silicate, 0.7 parts of sodium carboxymethyl cellulose, and 9 parts of cobalt black material.

[0062] A method for preparing stone-like ceramic tiles comprises the following steps:

[0063] (1) The raw materials of the green body layer are weighed according to the ratio, and wet ball milled, and then spray granulated to obtain the green body layer powder; then the powder is spread on the bottom of the press, and pressed into shape using a stone-like mold with a concave-convex texture, and the surface powder is removed to obtain the green body layer;

[0064] (2) Weighing the raw materials of the top glaze layer and the transparent glaze layer according to the ratio and wet ball milling them to obtain the top glaze and the transparent glaze. The viscosity of the top glaze is 9 mPas and the particle size is 8 μm.

[0065] (3) Using electrostatic spraying, the top glaze and the transparent glaze prepared in step (2) are sprayed on the upper surface of the green body layer prepared in step (1) to form a top glaze layer and a transparent glaze layer, thereby obtaining a semi-finished product; wherein: the spray gun pressure is 0.4 MPa, and the glaze amount of the top glaze is 70 g / m 2 The amount of transparent glaze is 50g / m 2 ;

[0066] (4) The semi-finished product obtained in step (3) was fired at 1190° C. for 55 minutes to obtain the stone-like ceramic tile of this comparative example.

[0067] The only difference between Comparative Example 1 and Example 1 is that the green body layer of Comparative Example 1 is not layered and no diatomaceous earth is added to the green body layer.

[0068] Comparative Example 2

[0069] A stone-like ceramic tile comprises, from bottom to top, a body layer, a surface glaze layer and a transparent glaze layer, wherein the body layer comprises a lower body and an upper body, and the thickness ratio of the lower body layer to the upper body layer is 8:2.

[0070] The raw material components of the lower green body layer are as follows by weight: 45.3 parts of clay, 18.6 parts of feldspar, 24.5 parts of quartz, 4.7 parts of talc, 6 parts of bauxite, 0.15 parts of sodium carboxymethyl cellulose, 0.25 parts of sodium tripolyphosphate, and 0.5 parts of polyacrylamide.

[0071] The raw material components of the upper green body layer are as follows by weight: 45.3 parts of clay, 18.6 parts of feldspar, 24.5 parts of quartz, 4.7 parts of talc, 6 parts of bauxite, 0.1 parts of sodium carboxymethyl cellulose, 0.25 parts of sodium tripolyphosphate, 0.5 parts of polyacrylamide, and 8 parts of diatomaceous earth.

[0072] In parts by weight, the raw material components of the surface glaze layer are: 34.5 parts of quartz, 22.5 parts of feldspar, 13.8 parts of aluminum oxide, 10.6 parts of calcium carbonate, 2.4 parts of calcined talc, 3.7 parts of zinc oxide, 2.8 parts of zirconium silicate, 0.7 parts of sodium carboxymethyl cellulose, and 9 parts of cobalt black material.

[0073] A method for preparing stone-like ceramic tiles comprises the following steps:

[0074] (1) The raw materials of the upper and lower green bodies are weighed and wet-milled according to the ratio, and then spray-granulated to obtain the upper green body layer powder and the lower green body layer powder; then, they are sequentially spread on the bottom of the press, pressed into shape using a stone-like mold with a concave-convex texture, and the surface powder is removed to obtain the green body layer;

[0075] (2) Weighing the raw materials of the top glaze layer and the transparent glaze layer according to the ratio and wet ball milling them to obtain the top glaze and the transparent glaze. The viscosity of the top glaze is 9 mPas and the particle size is 8 μm.

[0076] (3) Applying the top glaze and the transparent glaze prepared in step (2) on the upper surface of the body layer prepared in step (1) in sequence by pouring glaze to form a top glaze layer and a transparent glaze layer to obtain a semi-finished product; wherein: the amount of the top glaze applied is 70g / m 2 The amount of transparent glaze is 50g / m 2 ;

[0077] (4) The semi-finished product obtained in step (3) was fired at 1190° C. for 55 minutes to obtain the stone-like ceramic tile of this comparative example.

[0078] The only difference between Comparative Example 2 and Example 1 is that Comparative Example 2 adopts the glazing method of pouring glaze.

[0079] Comparative Example 3

[0080] A stone-like ceramic tile comprises, from bottom to top, a body layer, a surface glaze layer and a transparent glaze layer, wherein the body layer comprises a lower body and an upper body, and the thickness ratio of the lower body layer to the upper body layer is 8:2.

[0081] The raw material components of the lower green body layer are as follows by weight: 45.3 parts of clay, 18.6 parts of feldspar, 24.5 parts of quartz, 4.7 parts of talc, 6 parts of bauxite, 0.15 parts of sodium carboxymethyl cellulose, 0.25 parts of sodium tripolyphosphate, and 0.5 parts of polyacrylamide.

[0082] The raw material components of the upper green body layer are as follows by weight: 45.3 parts of clay, 18.6 parts of feldspar, 24.5 parts of quartz, 4.7 parts of talc, 6 parts of bauxite, 0.1 parts of sodium carboxymethyl cellulose, 0.25 parts of sodium tripolyphosphate, 0.5 parts of polyacrylamide, and 8 parts of diatomaceous earth.

[0083] In parts by weight, the raw material components of the top glaze layer are: 53.7 parts of quartz, 5.4 parts of feldspar, 21.4 parts of aluminum oxide, 2.3 parts of calcium carbonate, 2.7 parts of calcined talc, 4.8 parts of zinc oxide, 0.7 parts of sodium carboxymethyl cellulose, and 9 parts of cobalt black material. The glaze viscosity of the top glaze is 15 mPas.

[0084] The preparation method of the stone-like ceramic tile of Comparative Example 3 is the same as that of Example 1. The only difference between the two is that the raw material components of the surface glaze layer used in Comparative Example 3 are different, resulting in a higher viscosity of the glaze.

[0085] Comparative Example 4

[0086] A stone-like ceramic tile comprises, from bottom to top, a body layer, a surface glaze layer and a transparent glaze layer.

[0087] The raw material components of the green body layer are as follows by weight: 45.3 parts of clay, 18.6 parts of feldspar, 24.5 parts of quartz, 4.7 parts of talc, 6 parts of bauxite, 0.15 parts of sodium carboxymethyl cellulose, 0.25 parts of sodium tripolyphosphate, 0.5 parts of polyacrylamide, and 8 parts of diatomaceous earth.

[0088] In parts by weight, the raw material components of the surface glaze layer are: 34.5 parts of quartz, 22.5 parts of feldspar, 13.8 parts of aluminum oxide, 10.6 parts of calcium carbonate, 2.4 parts of calcined talc, 3.7 parts of zinc oxide, 2.8 parts of zirconium silicate, 0.7 parts of sodium carboxymethyl cellulose, and 9 parts of cobalt black material.

[0089] The preparation method of the stone-like ceramic tile of Comparative Example 4 is the same as that of Comparative Example 1.

[0090] The only difference between the stone-like ceramic tile of Comparative Example 4 and Example 1 is that the green body layer of Comparative Example 4 is not layered, and the diatomaceous earth is evenly distributed in the green body layer.

[0091] Performance Testing

[0092] The stone-like ceramic tile samples prepared in Examples 1-3 and Comparative Examples 1-4 were tested for water absorption and mechanical properties, and their glaze quality was observed. The compressive strength of the green and finished tiles was tested in accordance with GT / B 4740-1999, Test Methods for Compressive Strength of Ceramic Materials; the water absorption of the samples was tested in accordance with GB / T 4100-2015, Ceramic Tiles. The test results are shown in Table 1.

[0093] Table 1: Comparative performance of green bodies and samples of Examples 1-3 and Comparative Examples 1-5

[0094]

[0095] As shown in Table 1, the products produced in Examples 1-3 have uniform glaze thickness, smooth and even glaze surfaces, and realistic stone-like three-dimensional effects. The products also have low water absorption rates, and both the green and finished products exhibit high compressive strength. However, the products in Comparative Examples 1-4 exhibit certain defects due to the lack of diatomaceous earth addition, the use of a pour-on glazing method, excessively high viscosity of the top glaze layer, or the lack of layered green layers. Their water absorption rates and mechanical properties also fall short of those of Examples 1-3.

[0096] For those skilled in the art to which the present invention belongs, a number of simple deductions or substitutions can be made without departing from the concept of the present invention, without having to resort to creative work. Therefore, based on the disclosure of the present invention, simple improvements made by those skilled in the art to the present invention should be within the scope of protection of the present invention. The above embodiments are preferred embodiments of the present invention, and all processes similar to the present invention and equivalent changes made should fall within the scope of protection of the present invention.

Claims

1. A stone-like ceramic tile, characterized in that: From bottom to top, it includes a lower body layer, an upper body layer, a top glaze layer, and a transparent glaze layer; the raw material components of the upper body layer contain diatomaceous earth, and the top glaze layer and the transparent glaze layer are respectively formed by electrostatic spraying of the top glaze and the transparent glaze; the glaze viscosity of the top glaze is 8-12 mPas; The raw material components of the glaze are as follows, by weight: 30-45 parts of quartz, 20-25 parts of feldspar, 10-15 parts of aluminum oxide, 8-13 parts of calcium carbonate, 1-4 parts of calcined talc, 3-5 parts of zinc oxide, 1-3 parts of zirconium silicate, 0.5-1 parts of sodium carboxymethyl cellulose, and 8-12 parts of cobalt black material; The raw material components of the lower green body layer include, by weight: 30-60 parts of clay, 10-25 parts of feldspar, 20-35 parts of quartz, 2-5 parts of talc, 3-8 parts of bauxite, 0.1-0.3 parts of sodium carboxymethyl cellulose, 0.2-0.3 parts of sodium tripolyphosphate, and 0.3-0.7 parts of polyacrylamide; The raw material components of the upper green body layer are prepared by adding 8-15 wt % of diatomaceous earth to the raw material components of the upper green body layer.

2. The stone-like ceramic tile according to claim 1, characterized in that: The thickness ratio of the upper green body layer to the lower green body layer is (1-3):(7-9).

3. The stone-like ceramic tile according to claim 1, characterized in that: The particle size of the surface glaze and the transparent glaze are both 5-10 μm.

4. A method for preparing stone-like ceramic tiles, characterized in that: The preparation method is used to prepare the stone-like ceramic tile according to any one of claims 1 to 3, comprising the following steps: (1) The raw materials for preparing the upper green body layer and the lower green body layer are respectively made into powders, and are pressed into shape using a stone-like mold with a concave-convex texture to obtain the green body layer; (2) spraying a top glaze and a transparent glaze in sequence on the upper surface of the green body layer by electrostatic spraying to form a top glaze layer and a transparent glaze layer to obtain a semi-finished product; (3) The semi-finished product is put into a kiln for firing to obtain the stone-like ceramic tile.

5. The method for preparing the stone-like ceramic tile according to claim 4, characterized in that: In step (2), the glaze amount of the glaze is 70-100g / m 2 The amount of transparent glaze applied is 50-70g / m 2 .

6. The method for preparing the stone-like ceramic tile according to claim 4, wherein: In step (2), the atomization pressure of the electrostatic glaze spraying is 0.3-0.5 MPa.

7. The method for preparing the stone-like ceramic tile according to claim 4, characterized in that: In step (3), the calcination temperature is 1150-1220°C.

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