Preparation method of a tile with an ultra-thin fabric and a three-dimensional effect

Abstract

The present invention relates to a method for preparing ultra-thin fabric ceramic tiles with three-dimensional effects. The method for preparing ultra-thin fabric ceramic tiles with three-dimensional effects comprises the following steps: applying an ultra-thin fabric layer containing colored particles and metal dry particles on a base material layer, pressing and molding to obtain a brick blank with colored particles and metal dry particles embedded on the surface; the thickness of the ultra-thin fabric layer is 0.6-0.8 mm; applying ultra-thin high-white surface glaze on the surface of the brick blank to form a surface glaze layer; inkjet printing a printing layer on the surface glaze layer; applying a composite glaze on the surface of the brick blank printed with the printing layer; throwing flashing dry particles on the surface of the blank with the composite glaze to form a flashing surface effect; firing to obtain the ultra-thin fabric ceramic tiles with three-dimensional effects.

Description

Technical Field

[0001] The present invention belongs to the field of building ceramics, and particularly relates to a preparation method of a tile with ultra-thin cloth laying and three-dimensional effect. Background Art

[0002] With the development of the building ceramics market, there are more and more types of building decoration materials, and consumers also put forward higher requirements for the brick body material, pattern level, color pattern, and decorative effect. The fully polished glazed tile is widely loved by consumers for its rich color patterns and vivid patterns. However, the outermost layer of the fully polished glazed tile is a transparent or semi-transparent glaze layer, which greatly affects the wear resistance of the tile, and the three-dimensional effect of the fully polished glazed tile is usually poor. Summary of the Invention

[0003] The purpose of the present invention is to provide a preparation method of a tile with ultra-thin cloth laying and three-dimensional effect. By adopting the ultra-thin secondary cloth laying technology combined with the antique process, through various decorations of colored particles, metal dry particles, flash dry particles and inkjet patterns, the brick surface has a strong three-dimensional sense, and at the same time, the wear resistance, anti-slip and pollution resistance of the tile are improved.

[0004] In the first aspect, the present invention provides a preparation method of a tile with ultra-thin cloth laying and three-dimensional effect, and the preparation method includes the following steps:

[0005] Lay an ultra-thin fabric layer containing colored particles and metal dry particles on the base material layer, and press and form to obtain a brick blank with colored particles and metal dry particles embedded on the surface; the thickness of the ultra-thin fabric layer is 0.6 - 0.8 mm;

[0006] Lay an ultra-thin high-white surface glaze on the surface of the brick blank to form a surface glaze layer;

[0007] Inkjet print a printing layer on the surface glaze layer;

[0008] Apply a composite glaze on the surface of the brick blank printed with the printing layer;

[0009] Sprinkle flash dry particles on the surface of the green body applied with the composite glaze to form a flash surface effect;

[0010] Fire to obtain the tile with ultra-thin cloth laying and three-dimensional effect.

[0011] Preferably, the raw materials of the ultra-thin fabric layer include: 96.2 - 97.39 wt% of fabric, 2.6 - 3.79 wt% of colored particle material, and 0.01 - 0.013 wt% of metal dry particles.

[0012] Preferably, the chemical composition of the fabric includes: by mass percentage, loss on ignition: 3.7 - 4.5%; SiO2: 66.0 - 70.0%; Al2O3: 18.0 - 21.0%; Fe2O3: 0.4 - 0.9%; TiO2: 0.1 - 0.3%; CaO: 0.2 - 0.5%; MgO: 0.5 - 1.2%; K2O: 2.5 - 3.5%; Na2O: 2.2 - 3.8%;

[0013] The particle size distribution of the fabric includes: by mass percentage, residue on 20 - mesh sieve < 2%, residue on 40 - mesh sieve 34 - 50%, residue on 60 - mesh sieve 80 - 92%, residue on 100 - mesh sieve > 95%, and the residue of each mesh number is the cumulative value.

[0014] Preferably, the chemical composition of the metal dry particles includes: by mass percentage, loss on ignition: 28.2 - 30.8%; SiO2: 21 - 23%; Al2O3: 7.8 - 9.2%; K2O: 0.32 - 0.54%; Na2O: 1.2 - 2.5%; CaO: 3.2 - 4.3%; MgO: 0.42 - 0.48%; P2O5: 16.8 - 18.2%; Fe2O3: 11.6 - 13.2%; SO3: 1.34 - 2.02%; the minimum particle size of the colored particle material and the metal dry particles > 0.7 mm.

[0015] Preferably, the chemical composition of the ultra - thin high - white surface glaze includes: by mass percentage, loss on ignition: 1.2 - 2.0%; SiO2: 44.6 - 48.6%; Al2O3: 27.3 - 31.4%; K2O: 2.1 - 3.75%; Na2O: 1.2 - 2.6%; Li2O: 2.4 - 3.6%; CaO: 3.0 - 4.8%; MgO: 0.8 - 1.4%; P2O5: 3.1 - 4.5%; ZrO2: 7.6 - 9.3%;

[0016] The raw material composition of the ultra - thin high - white surface glaze includes: by mass percentage, potassium feldspar: 20 - 29%; lithium porcelain stone: 6 - 12%; nepheline: 8 - 12%; quartz: 12 - 15%; kaolin: 6 - 8%; calcined kaolin: 8 - 12%; calcined alumina: 15 - 18%; calcined talc: 2 - 4%; calcium phosphate: 6 - 8%; zirconium silicate: 8 - 12%.

[0017] Preferably, the raw material composition of the composite glaze includes: by mass percentage, protective glaze: 8 - 15%; wear - resistant dry particles: 16 - 30%; suspending agent: 55 - 74%;

[0018] The chemical composition of the composite glaze includes: by mass percentage, loss on ignition: 2.3 - 4.5%; SiO2: 45 - 50%; Al2O3: 18 - 22%; K2O: 3.6 - 5.2%; Na2O: 1.8 - 2.8%; CaO: 1.8 - 3.2%; MgO: 3.5 - 4.6%; ZnO: 6.2 - 7.6%; BaO: 8.8 - 10.2%; SrO: 1.4 - 2.1%; B2O3: 2.2 - 3.6%.

[0019] Preferably, the chemical composition of the protective glaze includes: by mass percentage, loss on ignition: 3.6 - 4.5%; SiO2: 45.2 - 48.7%; Al2O3: 12.6 - 15.8%; K2O: 2.8 - 4.6%; Na2O: 2.2 - 3.5%; CaO: 1.4 - 2.8%; MgO: 4.5 - 5.6%; ZnO: 10.2 - 13.6%; BaO: 13.6 - 16.4%;

[0020] The chemical composition of the wear-resistant dry particles includes: by mass percentage, loss on ignition: 1.2 - 2.3%; SiO2: 43.2 - 47.1%; Al2O3: 21.2 - 24.6%; K2O: 5.2 - 6.8%; Na2O: 1.8 - 2.4%; CaO: 2.3 - 3.6%; MgO: 4.2 - 6.7%; ZnO: 4.2 - 6.6%; BaO: 6.5 - 8.5%; SrO: 2.4 - 3.7%; B2O3: 3.9 - 6.1%.

[0021] Preferably, the chemical composition of the flash dry particles includes: by mass percentage, loss on ignition: 2.2 - 3.4%; SiO2: 48 - 55.8%; Al2O3: 15 - 18%; CaO: 8 - 13%; K2O: 6 - 9%; Na2O: 0 - 3%; MgO: 3 - 5%; ZnO: 4 - 6%; SrO: 6 - 9%;

[0022] The raw material composition of the flash dry particles includes: by mass percentage, potassium feldspar: 35 - 43.8%; nepheline: 8 - 12%; quartz: 2 - 4%; kaolin: 0 - 2%; calcite: 4 - 6%; calcined alumina: 8 - 14%; calcined talc: 7 - 13%; wollastonite: 15 - 20%; zinc oxide: 3 - 7.5%; strontium oxide: 9.2 - 12.5%;

[0023] The particle size of the flash dry particles is 60 - 100 mesh, and the application amount is 3 - 5 g / m 2 .

[0024] Preferably, the maximum firing temperature is 1170 - 1180 °C, and the firing time is 48 - 52 minutes.

[0025] Second aspect, the present invention provides a tile made of the ultrathin fabric obtained according to the above preparation method and having a three-dimensional effect. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 and Figure 2 is the surface effect diagram of the tile sample prepared by the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0027] The present invention is further illustrated by the following embodiments. It should be understood that the following embodiments are only used to illustrate the present invention and do not limit the present invention. Without special instructions, each percentage content refers to the mass percentage content. The following exemplarily describes the preparation method of the tile made of the ultrathin fabric and having a three-dimensional effect according to the present invention.

[0028] Lay the bottom material in the mold to form a bottom material layer. The chemical composition of the bottom material may include: by mass percentage, loss on ignition: 3.7 - 4.5%; SiO2: 68.0 - 72.0%; Al2O3: 17.0 - 19.0%; Fe2O3: 0.6 - 0.9%; TiO2: 0.1 - 0.3%; CaO: 0.4 - 0.7%; MgO: 0.3 - 0.8%; K2O: 2.5 - 3.2%; Na2O: 2.8 - 3.8%.

[0029] The moisture content of the bottom material can be controlled to be 6.45 - 7.25 wt%. When the moisture content of the bottom material is within the above range, it can effectively avoid the phenomenon of delamination when the press presses the green body and sticking to the mold, resulting in difficult demolding.

[0030] The particle size distribution of the bottom material includes: by mass percentage, the residue on the 20-mesh sieve < 2%, the residue on the 40-mesh sieve is 30 - 45%, the residue on the 60-mesh sieve is 75 - 85%, and the residue on the 100-mesh sieve > 92%. The residue of each mesh number is the cumulative value. By designing the above particle size distribution of the bottom material, it can still ensure the brick shape and strength after the brick blank is fired after being combined with the subsequent ultrathin fabric layer.

[0031] The bottom material can be laid in the mold of the press cavity to form a bottom material layer. The thickness of the bottom material layer can be 10.4 - 10.9 mm. Controlling the thickness of the bottom material layer within the above range can ensure that the pressed brick blank has better strength, so that the strength of the dried brick blank reaches 0.8 - 1.2 MPa.

[0032] Lay an ultrathin fabric layer on the bottom material layer. The raw materials of the ultrathin fabric layer include fabric, colored particles and metal dry particles. According to the layout design effect, colored particles and metal dry particles are laid on the fabric. It is preferably to use the positive feeding method, which is beneficial to the colored particles and metal dry particles being embedded on the surface of the fabric.

[0033] As an example, the raw materials of the ultra-thin fabric layer include: 96.2 to 97.39 wt% of fabric, 2.6 to 3.79 wt% of colored granular material, and 0.01 to 0.013 wt% of metallic dry granules. Among them, if the mass ratio of the colored granules to the metallic dry granules is too large, the granules on the material surface will be too dense, affecting the decorative effect; if the mass ratio is too small, the three-dimensional effect of the material surface will be affected, also affecting the decorative effect.

[0034] The chemical composition of the fabric may include: by mass percentage, loss on ignition: 3.7 to 4.5%; SiO2: 66.0 to 70.0%; Al2O3: 18.0 to 21.0%; Fe2O3: 0.4 to 0.9%; TiO2: 0.1 to 0.3%; CaO: 0.2 to 0.5%; MgO: 0.5 to 1.2%; K2O: 2.5 to 3.5%; Na2O: 2.2 to 3.8%.

[0035] The whiteness of the fabric described in the present invention is controlled to be 50 to 54 degrees. Fabric raw materials with high whiteness can be selected. As an example, the raw material composition of the fabric may include: by mass percentage, sodium feldspar powder: 10 to 15%; high-white sand: 15 to 17%; water-ground sand: 7 to 11%; white talc powder: 1.5 to 3.5%; raw ore sand: 0 to 2%; medium-temperature sand: 13.5 to 16.5%; high-white bentonite: 0 to 2%; ball clay: 20 to 24%. It should be understood that the above are only examples of fabric raw materials, and fabric raw materials obtained by adjusting the fabric raw materials and making the chemical composition of the fabric meet the requirements can all be applicable to the present invention.

[0036] The particle size distribution of the fabric includes: by mass percentage, the residue on a 20-mesh sieve < 2%, the residue on a 40-mesh sieve is 34 to 50%, the residue on a 60-mesh sieve is 80 to 92%, and the residue on a 100-mesh sieve > 95%. The residue of each mesh number is the cumulative value. By designing the particle size distribution of the fabric, the formed ultra-thin fabric layer can be made more uniform and flat, the colored granules can form a stable three-dimensional structure after firing, and the defects on the brick surface after firing can be reduced, ensuring the stability of the brick shape structure and the strength of the brick blank.

[0037] One or more colored granular materials can be used. According to the color system requirements of the brick, the colored granules can be formed by adding one or more color powders to the fabric and granulating. Such as using color materials such as brown colorant, yellow colorant, orange colorant, black colorant, etc. As an example, the moisture content of the colored granules can be controlled to be 4.6 to 6.2 wt%. When the moisture content of the colored granules is within the above range, the colored granules can be effectively prevented from breaking and affecting the particle effect on the product surface.

[0038] The particle size of the colored granules is 8 to 20 mesh. Using colored granules with large particle sizes can make the particle effect on the product surface more excellent.

[0039] The chemical composition of the metal dry granules may include: by mass percentage, loss on ignition: 28.2 - 30.8%; SiO2: 21 - 23%; Al2O3: 7.8 - 9.2%; K2O: 0.32 - 0.54%; Na2O: 1.2 - 2.5%; CaO: 3.2 - 4.3%; MgO: 0.42 - 0.48%; P2O5: 16.8 - 18.2%; Fe2O3: 11.6 - 13.2%; SO3: 1.34 - 2.02%.

[0040] In an embodiment of the present invention, the minimum particle size of the colored granular material and the metal dry granules > 0.7 mm. Preferably, the minimum particle size of the colored granular material and the metal dry granules > 0.8 mm. As an example, the particle sizes of the colored granules and the metal dry granules are both 8 - 20 mesh.

[0041] The thickness of the ultra-thin fabric layer may be 0.6 - 0.8 mm. In the ultra-thin fabric layer of the present invention, since the colored granules and the metal dry granules have relatively high density and hardness with respect to the base material (which is related to the moisture content of the granules), and the minimum particle sizes of the colored granules and the metal dry granules are both greater than 0.7 mm, at least part of the colored granules and the metal dry granules are exposed on the fabric surface after cloth laying, and the colored granules and the metal dry granules will not all sink into the fabric during the pressing process, thereby obtaining a green body with colored granules and metal dry granules inlaid on the surface.

[0042] The green body containing the ultra-thin fabric layer and the base material layer is pressed into shape by a press to obtain a green body with colored granular material and metal dry granules inlaid on the surface. In the examples, a press of model Sacmi PH3590Y can be used. The specifications of the green body can be two specifications of 600 mm × 600 mm and 800 mm × 800 mm.

[0043] An ultra-thin high white surface glaze is applied on the surface of the green body to form a surface glaze layer. The chemical composition of the ultra-thin high white surface glaze may include: by mass percentage, loss on ignition: 1.2 - 2.0%; SiO2: 44.6 - 48.6%; Al2O3: 27.3 - 31.4%; K2O: 2.1 - 3.75%; Na2O: 1.2 - 2.6%; Li2O: 2.4 - 3.6%; CaO: 3.0 - 4.8%; MgO: 0.8 - 1.4%; P2O5: 3.1 - 4.5%; ZrO2: 7.6 - 9.3%.

[0044] The raw material composition of the ultra-thin high-white surface glaze may include: by mass percentage, potassium feldspar: 20-29%; lithium porcelain stone: 6-12%; nepheline: 8-12%; quartz: 12-15%; kaolin: 6-8%; calcined kaolin: 8-12%; calcined alumina: 15-18%; burnt talc: 2-4%; calcium phosphate: 6-8%; zirconium silicate: 8-12%. In the formula of the ultra-thin high-white surface glaze of the present invention, calcium phosphate Ca3(PO4)2 is introduced, and the whiteness of the surface glaze is improved through the phase separation and opacification of P2O5. On the other hand, introducing lithium porcelain stone can also promote the improvement of the whiteness of the surface glaze.

[0045] Ink directly printed on the green body is likely to spread, affecting clarity. After conventional high-white materials are fired, they turn yellow, making it difficult to present the layout effect. In some embodiments, the gloss of the ultra-thin high-white surface glaze after firing can be controlled to be 2.5-4 degrees, and the whiteness can be 71.2-73.6 degrees.

[0046] The ultra-thin high-white surface glaze can be applied to the surface of the brick blank through the spraying process. The specific gravity of the ultra-thin high-white surface glaze can be 1.13-1.16, and the spraying amount can be 98-120 g / m 2 . A high-pressure spraying cabinet can be used to achieve a better spraying effect. For example, the spraying pressure can be 3-5 MPa. If the specific gravity and spraying amount of the ultra-white high-white surface glaze exceed the above range, it will cause the high-white surface glaze layer to be too thick, covering the decorative effects of colored particles and metal particles.

[0047] An inkjet printing layer is formed on the surface glaze layer. The decorative process of inkjet printing is used to further increase the pattern texture of the brick surface. In some embodiments, fine carving ink is inkjet printed on the surface of the inkjet printed pattern layer. For example, multi-color inkjet printing of pattern colors and fine carving ink is carried out through a multi-channel inkjet printer. The inks used can include blue, reddish-brown, orange, lemon yellow, black, red, etc. The specific decorative patterns, textures, and color effects are determined according to design requirements. A digital inkjet printer (purchased from System S.p.A.) can be used for printing.

[0048] After inkjet printing, drying is carried out, such as electric drying. The drying temperature can be 250-280 °C, and the drying time can be 120-180 seconds.

[0049] A composite glaze is applied on the inkjet printing layer. That is, the composite glaze is evenly applied on the surface of the brick blank printed with the inkjet pattern. The raw material composition of the composite glaze includes: by mass percentage, protective glaze: 8-15%; wear-resistant dry particles: 16-30%; suspending agent: 55-74%. Among them, if the content of the protective glaze is too much, it will affect the wear resistance and anti-slip performance of the material surface; if the content is too little, it will affect the stain resistance of the material.

[0050] The chemical composition of the composite glaze includes: by mass percentage, loss on ignition: 2.3 - 4.5%; SiO2: 45 - 50%; Al2O3: 18 - 22%; K2O: 3.6 - 5.2%; Na2O: 1.8 - 2.8%; CaO: 1.8 - 3.2%; MgO: 3.5 - 4.6%; ZnO: 6.2 - 7.6%; BaO: 8.8 - 10.2%; SrO: 1.4 - 2.1%; B2O3: 2.2 - 3.6%.

[0051] The chemical composition of the protective glaze may include: by mass percentage, loss on ignition: 3.6 - 4.5%; SiO2: 45.2 - 48.7%; Al2O3: 12.6 - 15.8%; K2O: 2.8 - 4.6%; Na2O: 2.2 - 3.5%; CaO: 1.4 - 2.8%; MgO: 4.5 - 5.6%; ZnO: 10.2 - 13.6%; BaO: 13.6 - 16.4%.

[0052] The raw material composition of the protective glaze includes: by mass percentage, potassium feldspar: 25 - 35%; albite: 7 - 9%; quartz: 3 - 5%; kaolin: 8 - 12%; dolomite: 4 - 6%; calcined kaolin: 6 - 12%; burnt talc: 4 - 6%; barium carbonate: 18 - 22%; zinc oxide: 9 - 13%; corundum: 3 - 5%.

[0053] Higher contents of ZnO and BaO in the protective glaze contribute to improving the ink color development. Additionally, the introduction of micron-sized corundum enhances the wear resistance of the protective glaze without affecting the stain resistance. As an example, the particle size of the corundum can be 40 - 60 μm.

[0054] The chemical composition of the wear-resistant dry particles may include: by mass percentage, loss on ignition: 1.2 - 2.3%; SiO2: 43.2 - 47.1%; Al2O3: 21.2 - 24.6%; K2O: 5.2 - 6.8%; Na2O: 1.8 - 2.4%; CaO: 2.3 - 3.6%; MgO: 4.2 - 6.7%; ZnO: 4.2 - 6.6%; BaO: 6.5 - 8.5%; SrO: 2.4 - 3.7%; B2O3: 3.9 - 6.1%.

[0055] The suspending agent can be printing oil with good suspending property. By adding the suspending agent, the suspending property of the composite glaze can be improved, and precipitation of the wear-resistant dry particles in the composite glaze can be avoided.

[0056] It should be noted that generally, it is difficult to achieve both good color development and high abrasion resistance for the tile protective glaze. The main reason is that to improve the abrasion resistance of the tile surface, it is often necessary to increase the aluminum content in the protective glaze formulation or promote crystallization on the glaze surface. However, too high an aluminum content or crystallization on the glaze surface is not conducive to ink color development. In the formulation of the composite glaze of the present invention, the introduction of ZnO, BaO, B2O3, SrO, etc. can better improve ink color development, and by promoting the crystallization of the composite glaze after firing, the abrasion resistance of the product surface can be improved. A high content of Al2O3 can also synergistically improve the abrasion resistance of the product surface.

[0057] The composite glaze can be applied to the brick surface with color patterns by spraying glaze process. The specific gravity of the composite glaze can be 1.28 - 1.32, and the glaze application amount can be 250 - 275 g / m 2 . If the application amount of the composite glaze is too much, it will affect the transparency of the product surface; if the application amount is too little, the covering effect of the product surface will be poor.

[0058] The glaze surface gloss of the composite glaze after firing is 2 - 3 degrees, and the stain resistance is grade 5.

[0059] Flash dry particles are thrown on the green body with the composite glaze to form a flash surface effect. The chemical composition of the flash dry particles can include: by mass percentage, loss on ignition: 2.2 - 3.4%; SiO2: 48 - 55.8%; Al2O3: 15 - 18%; CaO: 8 - 13%; K2O: 6 - 9%; Na2O: 0 - 3%; MgO: 3 - 5%; ZnO: 4 - 6%; SrO: 6 - 9%.

[0060] The raw material composition of the flash dry particles includes: by mass percentage, potassium feldspar: 35 - 43.8%; nepheline: 8 - 12%; quartz: 2 - 4%; kaolin: 0 - 2%; calcite: 4 - 6%; calcined alumina: 8 - 14%; calcined talc: 7 - 13%; wollastonite: 15 - 20%; zinc oxide: 3 - 7.5%; strontium oxide: 9.2 - 12.5%.

[0061] The particle size of the flash dry particles is 60 - 100 mesh. If the particle size of the flash dry particles is too large, it is easy to form flakes; if the particle size is too small, the flash effect is not obvious.

[0062] The present invention uses a glaze spraying cabinet instead of a cloth applicator to apply the flash dry particles. The application amount of the flash dry particles is 3 - 5 g / m 2 . By controlling the application amount and application method of the flash dry particles, the flash dry particles can form a sparse starlight effect on the glaze surface, thus avoiding the influence of excessive flash dry particles on the decoration of the colored particles and metal dry particles on the brick surface.

[0063] Fired in a kiln. Among them, the highest firing temperature is 1170 - 1180 °C, and the firing time is 48 - 52 minutes. The water absorption rate of the fired ceramic tile can be controlled within 0.5wt%. If the firing temperature is too high, it will affect the wear resistance and anti-slip performance of the product surface; if the firing temperature is too low, it will affect the transparency of the product surface.

[0064] Edge grinding, grading and packing.

[0065] In summary, the method of the present invention adopts the secondary feeding method of the polished tile production process. After laying the base material, the surface material, colored particles and metal dry particles are laid by the ultra-thin fabric technology. The ultra-thin fabric reduces the thickness of the surface material layer to 0.6 - 0.8 mm. After being pressed by a press, a green body with colored particles and metal dry particles embedded on the surface is obtained. The various decorations of the colored particles, metal dry particles and flash dry particles and the inkjet pattern make the surface have a strong three-dimensional sense, so as to obtain a ceramic tile with ultra-thin fabric and three-dimensional effect. Moreover, after the composite glaze is fired, the wear resistance, anti-slip performance and pollution resistance of the ceramic tile surface are improved, integrating multiple functions.

[0066] The following further lists embodiments to illustrate the present invention in detail. It should also be understood that the following embodiments are only used to further illustrate the present invention and cannot be construed as limiting the protection scope of the present invention. Some non-essential improvements and adjustments made by those skilled in the art based on the above content of the present invention all belong to the protection scope of the present invention. The specific process parameters and the like in the following examples are also only an example within a suitable range, that is, those skilled in the art can make selections within a suitable range through the description in this article, rather than being limited to the specific values in the following examples.

[0067] Example 1

[0068] The preparation method of the ultra-thin fabric and three-dimensional effect ceramic tile includes the following steps:

[0069] 1. Lay the base material in the press die cavity to form a base material layer. The moisture content of the base material is 7.25wt%. The thickness of the base material layer is 10.6 mm.

[0070] 2. Use a multi-tube feeding system to sequentially lay the surface material, various colored particles and metal dry particles on the base material layer to form an ultra-thin surface material layer. The raw materials of the ultra-thin surface material layer include: 96.85wt% of the surface material, 3.14wt% of the colored particle material and 0.01wt% of the metal dry particles. The particle size distribution of the surface material includes: in terms of mass percentage, the residue on a 20-mesh sieve < 1%, the residue on a 40-mesh sieve is 34 - 49%, the residue on a 60-mesh sieve is 80 - 92%, and the residue on a 100-mesh sieve > 95%. The residue of each mesh number is the cumulative value. The minimum dry particle of the colored particles and metal dry particles > 0.7 mm. The thickness of the ultra-thin surface material layer is 0.7 mm.

[0071] 3. Press and form by a press to obtain a green body with colored particles and metal dry particles embedded on the surface.

[0072] 4. Spray the ultra-thin high-white surface glaze using a high-pressure glazing cabinet. The spraying pressure is 4 MPa. The chemical composition of the ultra-thin high-white surface glaze includes: by mass percentage, loss on ignition: 1.43%; SiO2: 45.42%; Al2O3: 28.31%; K2O: 3.35%; Na2O: 2.33%; Li2O: 3.06%; CaO: 3.42%; MgO: 1.07%; P2O5: 3.82%; ZrO2: 7.79%. The specific gravity of the ultra-thin high-white surface glaze is 1.14, and the glazing amount is 120 g / m 2 .

[0073] 5. Inkjet print patterns and inkjet print engraving ink.

[0074] 6. Electro-dry after inkjet printing. The drying temperature is 260 °C. The drying time is 180 seconds.

[0075] 7. Apply the composite glaze. The chemical composition of the composite glaze includes: by mass percentage, loss on ignition: 3.3%, SiO2: 45.4%, Al2O3: 18%, K2O: 4.4%, Na2O: 2.4%, CaO: 2.8%, MgO: 3.8%, ZnO: 6.8%, BaO: 9.3%, SrO: 1.6%, B2O3: 2.2%. The specific gravity of the composite glaze is 1.30, and the glazing amount is 260 g / m 2 .

[0076] 8. Spin flash dry particles. The chemical composition of the flash dry particles includes: by mass percentage, loss on ignition: 2.4%; SiO2: 48.8%; Al2O3: 15.2%; CaO: 9.6%; K2O: 6.5%; Na2O: 1.6%; MgO: 4.2%; ZnO: 4.8%; SrO: 6.9%. The application amount of the flash dry particles is 4 g / m 2 .

[0077] 9. Fire in the kiln. The firing temperature is 1178 °C, and the firing time is 48 minutes.

[0078] 10. Edge grinding, grading and packing.

[0079] The tile sample prepared in Example 1 of the present invention has a strong three-dimensional sense and has the functions of wear resistance and anti-slip. The pollution resistance performance is measured to be Grade 5 according to the industry standard "National Ceramic and Plumbing Sanitary Ware Product Quality Supervision and Inspection Center". The water absorption rate of the fired tile is within 0.5 wt%.

[0080] Figure 1 and Figure 2 are the brick surface effect diagrams of the tile samples prepared by the present invention. It can be seen from the figure that the ceramic samples prepared by the present invention have a strong three-dimensional decorative effect.

[0081] Comparative Example 1

[0082] It is basically the same as Example 1, and the main difference is that the raw materials of the ultra-thin fabric layer include 98.25 wt% of fabric, 1.74 wt% of colored granular material, and 0.01 wt% of metal dry granules.

[0083] Due to the too small mass ratio of the colored granular material in the raw materials of the ultra-thin fabric layer in this Comparative Example 1, the surface three-dimensional effect of the prepared ceramic tile sample is poor.

[0084] Comparative Example 2

[0085] It is basically the same as Example 1, and the main difference is that the raw materials of the ultra-thin fabric layer include 95.24 wt% of fabric, 4.74 wt% of colored granular material, and 0.02 wt% of metal dry granules.

[0086] Due to the too large mass ratio of the colored granules and metal dry granules in the raw materials of the ultra-thin fabric layer in this Comparative Example 2, the particles on the surface of the prepared ceramic tile sample are too dense, and the decorative effect is poor.

[0087] Comparative Example 3

[0088] It is basically the same as Example 1, and the main difference is that the particle size distribution of the fabric includes: by mass percentage, the residue on the 20-mesh sieve is 2%, the residue on the 40-mesh sieve is 60%, the residue on the 60-mesh sieve is 95%, and the residue on the 100-mesh sieve is >95%, and the residue of each mesh number is the cumulative value.

[0089] Due to the too large particle size of the fabric used in this Comparative Example 3, delamination occurs during the pressing of the green body.

[0090] Comparative Example 4

[0091] It is basically the same as Example 1, and the main difference is that the thickness of the ultra-thin fabric layer is 0.3 mm.

[0092] Due to the too thin fabric layer in this Comparative Example 4, the prepared ceramic tile green body has the defect of leaking base material.

[0093] Comparative Example 5

[0094] It is basically the same as Example 1, and the main difference is that the thickness of the ultra-thin fabric layer is 1 mm.

[0095] Due to the too thick fabric layer in this Comparative Example 5, the cost of the prepared ceramic tile sample is too high, the effect of the colored dry granules and metal dry granules exposed on the surface of the fabric is not good, and the three-dimensional effect of the ceramic tile sample is poor.

[0096] Comparative Example 6

[0097] Basically the same as Example 1, with the difference that the chemical composition of the surface glaze includes: by mass percentage, loss on ignition: 1.2 - 2.0%; SiO2: 49.6 - 52.9%; Al2O3: 28.2 - 32.6%; K2O: 2.8 - 4.2%; Na2O: 1.8 - 3.2%; CaO: 3.6 - 4.8%; MgO: 0.8 - 1.4%; ZrO2: 5.8 - 6.8%.

[0098] Since calcium phosphate and lithium feldspar porcelain were not introduced into the surface glaze raw materials in Comparative Example 6, and the chemical composition hardly contains P2O5 and Li2O, the whiteness of the surface glaze after firing is 64.2 - 66.8 degrees, and the whiteness is poor. The expected decorative effect and function cannot be adjusted for the gray layout.

[0099] Comparative Example 7

[0100] Basically the same as Example 1, with the main difference that the chemical composition of the composite glaze includes: by mass percentage, loss on ignition: 2.5%; SiO2: 48.5%; Al2O3: 21%; K2O: 4.2%; Na2O: 2.4%; CaO: 2.6%; MgO: 5.4%; ZnO: 5.6%; BaO: 6.8%; SrO: 1.0%.

[0101] Since the contents of ZnO, BaO, B2O3, and SrO in the chemical composition of the composite glaze used in Comparative Example 7 are too low, the surface transparency and color difference of the prepared ceramic tile samples are poor.

Claims

1. A method for preparing a tile with an ultra-thin fabric and a three-dimensional effect, characterized in that, The preparation method comprises the following steps: An ultra-thin fabric layer containing colored particles and metal dry particles is applied on the base material layer, and pressed to obtain a brick blank with colored particles and metal dry particles embedded on the surface; the raw materials of the ultra-thin fabric layer include: 96.2-97.39 wt% of fabric, 2.6-3.79 wt% of colored particles and 0.01-0.013 wt% of metal dry particles; the thickness of the ultra-thin fabric layer is 0.6-0.8 mm, the minimum particle size of the colored particles and metal dry particles is greater than 0.7 mm, and at least part of the colored particles and metal dry particles are exposed on the fabric surface after the fabric is applied; the particle gradation of the fabric includes: in terms of mass percentage, 20 mesh sieve residue is less than 2%, 40 mesh sieve residue is 34-50%, 60 mesh sieve residue is 80-92%, 100 mesh sieve residue is greater than 95%, and the sieve residues of each mesh number are cumulative values; Applying ultra-thin high-white glaze on the surface of the brick to form a glaze layer; the chemical composition of the ultra-thin high-white glaze includes: in terms of mass percentage, loss on ignition: 1.2-2.0%; SiO2: 44.6-48.6%; Al2O3: 27.3-31.4%; K2O: 2.1-3.75%; Na2O: 1.2-2.6%; Li2O: 2.4-3.6%; CaO: 3.0-4.8%; MgO: 0.8-1.4% ; P2O5: 3.1-4.5%; ZrO2: 7.6-9.3%; The raw materials of the ultra-thin high-white glaze include: in terms of mass percentage, potassium feldspar: 20-29%; lithium porcelain stone: 6-12%; nepheline: 8-12%; quartz: 12-15%; kaolin: 6-8%; calcined kaolin: 8-12%; calcined alumina: 15-18%; burned talc: 2-4%; calcium phosphate: 6-8%; zirconium silicate: 8-12%; Inkjet printing a print layer on the glaze layer; The composite glaze is applied on the surface of the brick blank printed with the printing layer; the chemical composition of the composite glaze includes: in terms of mass percentage, loss on ignition: 2.3-4.5%; SiO2: 45-50%; Al2O3: 18-22%; K2O: 3.6-5.2%; Na2O: 1.8-2.8%; CaO: 1.8-3.2%; MgO: 3.5-4.6%; ZnO: 6.2-7.6%; BaO: 8.8-10.2%; SrO: 1.4-2.1%; B2O3: 2.2-3.6%; The flashing dry particles are thrown on the surface of the body to be coated with the composite glaze to form a flashing surface effect; After firing, the ultra-thin fabric and the ceramic tile with three-dimensional effect are obtained.

2. The preparation method according to claim 1, wherein The chemical composition of the fabric includes: in terms of mass percentage, loss on ignition: 3.7-4.5%; SiO2: 66.0-70.0%; Al2O3: 18.0-21.0%; Fe2O3: 0.4-0.9%; TiO2: 0.1-0.3%; CaO: 0.2-0.5%; MgO: 0.5-1.2%; K2O: 2.5-3.5%; Na2O: 2.2-3.8%.

3. The preparation method according to claim 1, characterized in that, The chemical composition of the metal dry granules includes: by mass percentage, loss on ignition: 28.2 - 30.8%; SiO2: 21 - 23%; Al2O3: 7.8 - 9.2%; K2O: 0.32 - 0.54%; Na2O: 1.2 - 2.5%; CaO: 3.2 - 4.3%; MgO: 0.42 - 0.48%; P2O5: 16.8 - 18.2%; Fe2O3: 11.6 - 13.2%; SO3: 1.34 - 2.02%.

4. The preparation method according to claim 1, characterized in that, The raw material composition of the composite glaze includes: by mass percentage, protective glaze: 8 - 15%; wear-resistant dry granules: 16 - 30%; suspending agent: 55 - 74%.

5. The preparation method according to claim 4, characterized in that, The chemical composition of the protective glaze includes: by mass percentage, loss on ignition: 3.6 - 4.5%; SiO2: 45.2 - 48.7%; Al2O3: 12.6 - 15.8%; K2O: 2.8 - 4.6%; Na2O: 2.2 - 3.5%; CaO: 1.4 - 2.8%; MgO: 4.5 - 5.6%; ZnO: 10.2 - 13.6%; BaO: 13.6 - 16.4%. The chemical composition of the wear-resistant dry granules includes: by mass percentage, loss on ignition: 1.2 - 2.3%; SiO2: 43.2 - 47.1%; Al2O3: 21.2 - 24.6%; K2O: 5.2 - 6.8%; Na2O: 1.8 - 2.4%; CaO: 2.3 - 3.6%; MgO: 4.2 - 6.7%; ZnO: 4.2 - 6.6%; BaO: 6.5 - 8.5%; SrO: 2.4 - 3.7%; B2O3: 3.9 - 6.1%.

6. The preparation method according to claim 1, characterized in that, The chemical composition of the flash dry granules includes: by mass percentage, loss on ignition: 2.2 - 3.4%; SiO2: 48 - 55.8%; Al2O3: 15 - 18%; CaO: 8 - 13%; K2O: 6 - 9%; Na2O: 0 - 3%; MgO: 3 - 5%; ZnO: 4 - 6%; SrO: 6 - 9%. The raw material composition of the flash dry granules includes: by mass percentage, potassium feldspar: 35 - 43.8%; nepheline: 8 - 12%; quartz: 2 - 4%; kaolin: 0 - 2%; calcite: 4 - 6%; calcined alumina: 8 - 14%; calcined talc: 7 - 13%; wollastonite: 15 - 20%; zinc oxide: 3 - 7.5%; strontium oxide: 9.2 - 12.5%. The particle size of the flash dry granules is 60 to 100 mesh, and the application amount is 3 to 5 g / m 2 .

7. The preparation method according to claim 1, characterized in that The maximum firing temperature is 1170 - 1180 °C, and the firing time is 48 - 52 minutes.

8. A tile with an ultra-thin fabric and a three-dimensional effect obtained by the preparation method according to claim 1.

Images