A wear-resistant polished glazed tile and its preparation method

Abstract

The present application relates to a wear-resistant polished glaze tile and a preparation method thereof. The wear-resistant polished glaze tile includes a body, and a bottom glaze layer and a wear-resistant polished glaze layer sequentially arranged on the body; the wear-resistant polished glaze layer is prepared from a wear-resistant polished glaze material. Based on the total weight of the wear-resistant polished glaze material, the preparation raw materials of the wear-resistant polished glaze material include the following components: 8-15 parts of frit, 10-15 parts of potassium feldspar, 1-3 parts of quartz powder, 5-15 parts of calcined talc, 5-10 parts of zinc oxide, 10-15 parts of wollastonite, 15-20 parts of kaolin, 1-3 parts of corundum micropowder, and 0.5-1 part of rare earth metal oxide; the rare earth metal oxide includes neodymium oxide and cerium oxide. A wear-resistant polished glaze layer is arranged on the surface of the wear-resistant polished glaze tile in the present application. By controlling the raw material composition in the glaze used for preparing the wear-resistant polished glaze layer, the wear-resistant polished glaze layer has high hardness and wear resistance, so that the wear-resistant polished glaze tile has good wear resistance and has a good market application prospect.

Description

Technical Field

[0001] This application relates to the technical field of ceramic preparation, and particularly relates to a wear-resistant polished glaze tile and a preparation method thereof. Background Art

[0002] A polished glaze tile is a high-grade building decoration material, which means that there is a glaze layer on the surface of the brick blank, and it is polished to become a product with a glossy or matte effect. The polished glaze tile combines the advantages of porcelain glazed tiles and polished tiles. It not only has rich and vivid patterns, but also has a smooth and bright surface. In the initial stage of its appearance, it was deeply welcomed by consumers due to its rich product colors and patterns and clear texture levels.

[0003] However, with the passage of time, some disadvantages of the polished glaze tile have gradually emerged. The most prominent one is the low wear resistance of the product, resulting in easy abrasion of the surface. When using the polished glaze tile as a floor decoration material, there are high requirements for the wear resistance of the glaze. The polished glaze tile prepared with glaze with low wear resistance is very easy to be abraded. For products with poor wear resistance, after a long time of use, the glossiness decreases very significantly, and the surface becomes dull, seriously affecting the aesthetics.

[0004] At present, the surface hardness and wear resistance of polished glaze products on the market are both poor, and the wear resistance is difficult to meet the requirements of consumers. In this regard, some enterprises solve this problem by thickening the glaze layer. However, with the thickening of the glaze layer, it will have a certain impact on products with a printing layer on the surface of the brick blank. At the same time, with the thickening of the glaze layer, the manufacturing cost is also increased, and because it needs to be polished, some bubbles will be enclosed in the thick glaze layer, and these bubbles will appear during the polishing process, affecting the appearance effect and stain resistance of the final product. Moreover, this method of thickening the glaze layer can only alleviate the problem of poor wear resistance of the glaze, and cannot fundamentally solve the wear resistance problem. Summary of the Invention

[0005] In order to solve the deficiencies of the prior art, this application provides a wear-resistant polished glaze tile. A wear-resistant polished glaze layer is provided on the surface of the wear-resistant polished glaze tile. The wear-resistant polished glaze layer has a high hardness and excellent wear resistance, so it can endow the wear-resistant polished glaze tile with good wear resistance.

[0006] Therefore, in the first aspect of this application, a wear-resistant polished glaze tile is provided. The wear-resistant polished glaze tile includes a blank body, and a bottom glaze layer and a wear-resistant polished glaze layer sequentially provided on the blank body; the wear-resistant polished glaze layer is made of wear-resistant polished glaze material. Based on the total weight of the wear-resistant polished glaze material, the preparation raw materials of the wear-resistant polished glaze material include the following components:

[0007] 8-15 parts of frit, 10-15 parts of potassium feldspar, 1-3 parts of quartz powder, 5-15 parts of calcined talc, 5-10 parts of zinc oxide, 10-15 parts of wollastonite, 15-20 parts of kaolin, 1-3 parts of corundum micropowder and 0.5-1 part of rare earth metal oxide; the rare earth metal oxide includes neodymium oxide and cerium oxide.

[0008] In this application, potassium feldspar, quartz powder, calcined talc, wollastonite, kaolin and corundum micropowder in the wear-resistant polishing glaze can provide SiO2, Al2O3 and MgO. During the subsequent sintering process, SiO2, Al2O3 and MgO will form mullite crystal phase and magnesium aluminate spinel phase. The two grow, develop and intertwine together at the sintering temperature, and then a dense network structure is formed, making the prepared wear-resistant polishing glaze layer have high hardness and wear resistance. Zinc oxide can improve the transparency and gloss of the glaze to a certain extent, and further improve the wear resistance and hardness of the wear-resistant polishing glaze layer. Frit is a small piece obtained by melting some raw materials into a glassy substance and then water quenching. As a flux, it can reduce the firing temperature of the glaze and improve the stability of the wear-resistant polishing glaze layer. Rare earth metal oxides - neodymium oxide and cerium oxide can synergistically improve the compactness of the network structure formed by the mullite crystal phase and magnesium aluminate spinel phase, and promote the discharge of gas during the preparation process, reduce the number of pores in the wear-resistant polishing glaze layer, and further improve the wear resistance and hardness of the wear-resistant polishing glaze layer.

[0009] In this application, the compositions of the green body and the base glaze in the wear-resistant polishing glaze are conventional compositions in the art. Those skilled in the art can make conventional selections and then prepare them by themselves or directly purchase them through commercial channels and use them.

[0010] In some embodiments, the mass ratio of neodymium oxide to cerium oxide is (0.5-1.5):(0.5-1.5). In some preferred embodiments, the mass ratio of neodymium oxide to cerium oxide is 1:1.

[0011] By controlling the mass relationship between neodymium oxide and cerium oxide in this application, the two can better play a synergistic effect and further improve the wear resistance and hardness of the wear-resistant polishing glaze layer.

[0012] In some embodiments, the content of the rare earth metal oxide in the wear-resistant polishing glaze is 0.8-1.2 wt%. In some preferred embodiments, the content of the rare earth metal oxide in the wear-resistant polishing glaze is 1.0 wt%.

[0013] By controlling the content of the rare earth metal oxide within the above range in this application, the rare earth metal oxide can better play its role, and further reduce the number of pores in the wear-resistant polishing glaze layer, and improve the wear resistance and hardness of the wear-resistant polishing glaze layer.

[0014] In some embodiments, based on the total weight of the frit, the raw materials for preparing the frit include the following components: 10-18 parts of potassium feldspar, 2-5 parts of raw talc, 2-4 parts of wollastonite, 8-10 parts of quartz powder, 8-10 parts of calcite, 5-8 parts of alumina, 1-3 parts of zinc oxide, 0.5-0.8 parts of yttrium carbonate, and 0.8-1.5 parts of lanthanum carbonate.

[0015] In the present application, the content of alumina in the frit is relatively high, which makes the frit have better wear resistance; zinc oxide, wollastonite, yttrium carbonate, and lanthanum carbonate in the frit can act as fluxes to synergistically reduce the firing temperature of the wear-resistant polishing glaze, and at the same time, yttrium carbonate and lanthanum carbonate can also synergistically promote the full discharge of gas during the melting process of the frit, making the wear resistance and comprehensive performance of the prepared wear-resistant polishing glaze layer better.

[0016] In the present application, the melting temperature during the preparation of the frit can be 1400-1500 °C. If the melting temperature is too low, the raw material components in the frit will not be fully melted, reducing its service performance; if the melting temperature is too high, it will not only cause waste, but also have a negative impact on the performance of the prepared frit.

[0017] In some embodiments, the mass ratio of zinc oxide, wollastonite, yttrium carbonate, and lanthanum carbonate is (3-5):(5-8):1:(1-3).

[0018] In some preferred embodiments, the mass ratio of zinc oxide, wollastonite, yttrium carbonate, and lanthanum carbonate is 4:6:1:2.

[0019] By optimizing the weight ratio of zinc oxide, wollastonite, yttrium carbonate, and lanthanum carbonate in the present application, the wear resistance of the wear-resistant polishing glaze layer can be further improved.

[0020] In some embodiments, the raw materials for preparing the frit further include 0.2-0.8 parts of manganese carbonate.

[0021] In some preferred embodiments, the raw materials for preparing the frit further include 0.5 parts of manganese carbonate.

[0022] In the present application, by adding manganese carbonate to the frit, manganese ions diffuse during the calcination process, and the diffused manganese ions can increase the forming rate of mullite crystal phase and magnesium aluminate spinel crystal phase in the wear-resistant polishing glaze layer, promoting the formation of a dense network structure inside the wear-resistant polishing glaze layer.

[0023] In some embodiments, the thickness of the wear-resistant polishing glaze layer is 0.1-0.3 mm.

[0024] In this application, the hardness and wear resistance of the wear-resistant polished glaze layer are good. Therefore, the thickness of the wear-resistant polished glaze layer does not need to be too thick. A thickness between 0.1 and 0.3 mm can endow the prepared wear-resistant polished glaze tile with excellent wear resistance, reduce the manufacturing cost, and improve the appearance effect of the product.

[0025] The second aspect of this application provides a preparation method of the wear-resistant polished glaze tile as described in the first aspect of this application. The method includes the following steps:

[0026] S1, applying a base glaze on the surface of the green body to form a base glaze layer;

[0027] S2, mixing the raw materials for preparing the wear-resistant polished glaze in proportion and then performing ball milling to obtain the wear-resistant polished glaze;

[0028] S3, applying the wear-resistant polished glaze on the surface of the base glaze layer to form a wear-resistant polished glaze layer;

[0029] S4, sintering and polishing the green body with the wear-resistant polished glaze layer applied thereon to obtain the wear-resistant polished glaze tile.

[0030] In this application, the methods of applying the base glaze on the surface of the green body and applying the wear-resistant polished glaze on the surface of the base glaze layer are conventional methods in the art. For example, the glazing method can be used.

[0031] In step S2 of this application, the ball milling medium used during ball milling can be a mixture of ethanol and water, the grinding balls are alumina grinding balls, and the ball milling time can be 30 to 100 min.

[0032] In some embodiments, the sintering temperature is 1100 to 1250 °C and the time is 1 to 2 h.

[0033] In this application, at this sintering temperature and time, the mullite crystal phase and magnesium aluminate spinel phase in the wear-resistant polished glaze layer can grow better, and the denseness of the fired wear-resistant polished glaze layer can be improved, making its wear resistance better.

[0034] The beneficial technical effects of the present application are as follows: SiO2, Al2O3, and MgO in the raw materials for preparing the wear-resistant glaze layer on the surface of the wear-resistant glazed tile provided by the present application will generate mullite crystal phase and magnesium aluminate spinel phase during the subsequent sintering process. The two grow, develop, and intertwine together at the sintering temperature, thereby generating a dense network structure, making the prepared wear-resistant glaze layer have high hardness and wear resistance. Neodymium oxide and cerium oxide can synergistically improve the density of the network structure formed by the mullite crystal phase and magnesium aluminate spinel phase, and promote the discharge of gas during the preparation process, reducing the number of pores in the wear-resistant glaze layer and further improving the wear resistance and hardness of the wear-resistant glaze layer. Zinc oxide, wollastonite, yttrium carbonate, and lanthanum carbonate in the frit can act as fluxes to synergistically reduce the firing temperature of the wear-resistant glaze material. At the same time, yttrium carbonate and lanthanum carbonate can also synergistically promote the full discharge of gas during the melting process of the frit, making the wear resistance and comprehensive performance of the prepared wear-resistant glaze layer better. Therefore, the wear-resistant glaze layer of the present application can endow the wear-resistant glazed tile with good wear resistance, greatly improving its wear resistance and having good market application prospects. Detailed Embodiments

[0035] To make the present application easier to understand, the following will further elaborate on the present application in combination with embodiments. These embodiments are only illustrative and are not limited to the application scope of the present application. The raw materials or components used in the present application can be obtained through commercial channels or conventional methods without special instructions.

[0036] Example 1: Preparation of Wear-Resistant Glazed Tile

[0037] (1) Preparation of wear-resistant glaze material:

[0038] Based on the total weight parts of the wear-resistant glaze material, the raw materials for preparing the wear-resistant glaze material are: 10 parts of frit, 12 parts of potassium feldspar, 2 parts of quartz powder, 10 parts of calcined talc, 8 parts of zinc oxide, 12 parts of wollastonite, 18 parts of kaolin, 2 parts of corundum micropowder, 0.4 part of neodymium oxide, and 0.4 part of cerium oxide; among them, the mass ratio of neodymium oxide to cerium oxide is 1:1, and the content of rare earth metal oxides (neodymium oxide and cerium oxide) in the wear-resistant glaze material is 1 wt%.

[0039] Based on the total weight of the frit, the raw materials for preparing the frit are: 15 parts of potassium feldspar, 3 parts of raw talc, 3 parts of wollastonite, 10 parts of quartz powder, 8 parts of calcite, 6 parts of alumina, 2 parts of zinc oxide, 0.5 part of yttrium carbonate, and 1 part of lanthanum carbonate; among them, the mass ratio of zinc oxide, wollastonite, yttrium carbonate, and lanthanum carbonate is 4:6:1:2.

[0040] Mix the above raw materials for preparing the wear-resistant glaze material and then perform ball milling. The ball milling medium used during ball milling can be a mixture of ethanol and water (the volume ratio of ethanol to water is 1:1), the grinding balls are alumina grinding balls, and the ball milling time can be 50 min to obtain the wear-resistant glaze material.

[0041] (2) Preparation of Wear-resistant Polished Glazed Tiles

[0042] Spray the bottom glaze (commercial product) on the surface of the commercially available green body to form a bottom glaze layer with a thickness of 0.5 mm. Then spray the wear-resistant polished glaze prepared in step (1) on the bottom glaze layer to form a wear-resistant polished glaze layer with a spraying thickness of 0.6 mm. Sinter the green body with the wear-resistant polished glaze layer at a sintering temperature of 1200 °C for 90 min. After cooling, polish the wear-resistant polished glaze layer to obtain the wear-resistant polished glazed tile. The thickness of the wear-resistant polished glaze layer in the polished wear-resistant polished glazed tile is 0.2 mm.

[0043] Example 2: Preparation of Wear-resistant Polished Glazed Tiles

[0044] The preparation process is basically the same as that of Example 1, except that the weight fraction of neodymium oxide in the raw materials for preparing the wear-resistant polished glaze is 0.2 parts and that of cerium oxide is 0.6 parts, and the mass ratio of neodymium oxide to cerium oxide is 0.5:1.5.

[0045] Example 3: Preparation of Wear-resistant Polished Glazed Tiles

[0046] The preparation process is basically the same as that of Example 1, except that the weight fraction of neodymium oxide in the raw materials for preparing the wear-resistant polished glaze is 0.6 parts and that of cerium oxide is 0.2 parts, and the mass ratio of neodymium oxide to cerium oxide is 1.5:0.5.

[0047] Example 4: Preparation of Wear-resistant Polished Glazed Tiles

[0048] The preparation process is basically the same as that of Example 1, except that the weight fraction of neodymium oxide in the raw materials for preparing the wear-resistant polished glaze is 0.3 parts and that of cerium oxide is 0.3 parts, the mass ratio of neodymium oxide to cerium oxide is 1:1, and the content of rare earth metal oxides (neodymium oxide and cerium oxide) in the wear-resistant polished glaze is 0.8 wt%.

[0049] Example 5: Preparation of Wear-resistant Polished Glazed Tiles

[0050] The preparation process is basically the same as that of Example 1, except that the weight fraction of neodymium oxide in the raw materials for preparing the wear-resistant polished glaze is 0.5 parts and that of cerium oxide is 0.5 parts, the mass ratio of neodymium oxide to cerium oxide is 1:1, and the content of rare earth metal oxides (neodymium oxide and cerium oxide) in the wear-resistant polished glaze is 1.3 wt%.

[0051] Example 6: Preparation of Wear-resistant Polished Glazed Tiles

[0052] The preparation process is basically the same as that of Example 1, except that the weight fraction of wollastonite in the raw materials for preparing the frit is 2.5 parts, the weight fraction of zinc oxide is 2.5 parts, and the mass ratio of zinc oxide, wollastonite, yttrium carbonate and lanthanum carbonate is 5:5:1:2.

[0053] Example 7: Preparation of Wear-resistant Polished Glazed Tiles

[0054] The preparation process is basically the same as that of Example 1, except that the weight fraction of zinc oxide in the raw materials for preparing the frit is 5 parts, and wollastonite is not included.

[0055] Example 8: Preparation of Wear-resistant Polished Glazed Tiles

[0056] The preparation process is basically the same as that of Example 1, except that the weight fraction of yttrium carbonate in the raw materials for preparing the frit is 1.5 parts, and lanthanum carbonate is not included.

[0057] Example 9: Preparation of Wear-resistant Polished Glazed Tiles

[0058] The preparation process is basically the same as that of Example 1, except that the weight fraction of lanthanum carbonate in the raw materials for preparing the frit is 1.5 parts, and yttrium carbonate is not included.

[0059] Example 10: Preparation of Wear-resistant Polished Glazed Tiles

[0060] The preparation process is basically the same as that of Example 1, except that the raw materials for preparing the frit further include 0.2 parts by weight of manganese carbonate.

[0061] Example 11: Preparation of Wear-resistant Polished Glazed Tiles

[0062] The preparation process is basically the same as that of Example 1, except that the raw materials for preparing the frit further include 0.5 parts by weight of manganese carbonate.

[0063] Example 12: Preparation of Wear-resistant Polished Glazed Tiles

[0064] The preparation process is basically the same as that of Example 1, except that the raw materials for preparing the frit further include 0.8 parts by weight of manganese carbonate.

[0065] Example 13: Preparation of Wear-resistant Polished Glazed Tiles

[0066] The preparation process is basically the same as that of Example 1, except that the sintering temperature is 1000 °C and the time is 90 min.

[0067] Example 14: Preparation of Wear-resistant Polished Glazed Tiles

[0068] The preparation process is basically the same as that of Example 1, except that the sintering temperature is 1300 °C and the time is 90 min.

[0069] Comparative Example 1: Preparation of Wear-resistant Polished Glazed Tiles

[0070] The preparation process is basically the same as that of Example 1, except that the weight fraction of neodymium oxide in the raw materials for preparing the wear-resistant polishing glaze is 0.8 parts, and cerium oxide is not included.

[0071] Comparative Example 2: Preparation of Wear-resistant Polished Glazed Tiles

[0072] The preparation process is basically the same as that of Example 1, except that the weight fraction of cerium oxide in the raw materials for preparing the wear-resistant polishing glaze is 0.8 parts, and neodymium oxide is not contained.

[0073] Comparative Example 3: Preparation of wear-resistant polished glazed tiles

[0074] The preparation process is basically the same as that of Example 1, except that neodymium oxide and cerium oxide are not contained in the raw materials for preparing the wear-resistant polishing glaze.

[0075] Test Example 1

[0076] The glaze hardness and wear resistance of the wear-resistant polished glazed tiles prepared in Examples 1-14 and Comparative Examples 1-3 were detected. The specific test methods are as follows:

[0077] The test method for glaze hardness is as follows: Using an HVS-1000 digital display microhardness tester, the glaze hardness of the wear-resistant polished glazed tiles prepared in Examples 1-14 and Comparative Examples 1-3 was tested respectively. The applied pressure was 5.9 N, and the test results are shown in Table 1.

[0078] The test method for wear resistance is as follows: The wear-resistant polished glazed tiles prepared in Examples 1-14 and Comparative Examples 1-3 were cut into circular test blocks with a diameter of 30 mm, and then the test blocks were fixed on a Minimet1000 testing machine for wear test. The abrasive was silicon carbide added with 5 mL of water. The rotation speed of the test block was 50 rpm, and the wear load was 5 N. The wear rate after 1 h of wear was tested. The specific test results are shown in Table 1.

[0079] Table 1

[0080]

[0081]

[0082] It can be seen from the detection results in Table 1 that the glaze hardness and wear resistance of the wear-resistant polished glaze tiles prepared in Examples 1-14 of this application are superior to those of Comparative Examples 1-3, indicating that adding neodymium oxide and cerium oxide simultaneously in the raw materials for preparing the wear-resistant polished glaze can significantly improve the hardness and wear resistance of the finally prepared wear-resistant polished glaze tiles. It can be seen from the detection results of Examples 1-5 that when the mass ratio of neodymium oxide and cerium oxide added in the wear-resistant polished glaze is 1:1 and the total content of neodymium oxide and cerium oxide is 1 wt%, it is more beneficial to improve the hardness and wear resistance of the finally prepared wear-resistant polished glaze tiles. It can be seen from the detection results of Examples 1, 6-9 that when zinc oxide, wollastonite, yttrium carbonate and lanthanum carbonate are added simultaneously in the frit of the wear-resistant polished glaze and the mass ratio is 4:6:1:2, the hardness and wear resistance of the wear-resistant polished glaze tiles can be better. It can be seen from the detection results of Examples 1, 10-12 that when manganese carbonate is added to the frit of the wear-resistant polished glaze, the hardness and wear resistance of the wear-resistant polished glaze tiles can be further improved, and when the weight fraction of manganese carbonate is 0.5 parts, the improvement effect is the best. It can be seen from the detection results of Examples 1, 13-14 that controlling the sintering temperature at 1100-1250 °C is more beneficial to improving the hardness and wear resistance of the wear-resistant polished glaze tiles.

[0083] It should be noted that the above-described embodiments are only used to explain this application and do not constitute any limitation to this application. This application has been described by referring to typical embodiments, but it should be understood that the words used therein are descriptive and explanatory words rather than limiting words. Modifications can be made to this application within the scope of the claims of this application as stipulated, and the present invention can be revised without departing from the scope and spirit of this application. Although the application described therein relates to specific methods, materials and embodiments, it does not mean that this application is limited to the specific examples disclosed therein. On the contrary, this application can be extended to all other methods and applications with the same functions.

Claims

1. A wear-resistant polished glazed tile, characterized in that, The wear-resistant polished glaze tile comprises a body, and a bottom glaze layer and a wear-resistant polished glaze layer which are sequentially arranged on the body; the wear-resistant polished glaze layer is prepared from a wear-resistant polished glaze material, and based on the total weight of the wear-resistant polished glaze material, the preparation raw materials of the wear-resistant polished glaze material comprise the following components: 8-15 parts of frit, 10-15 parts of potassium feldspar, 1-3 parts of quartz powder, 5-15 parts of calcined talc, 5-10 parts of zinc oxide, 10-15 parts of wollastonite, 15-20 parts of kaolin, 1-3 parts of corundum micropowder and 0.5-1 part of rare earth metal oxide; the rare earth metal oxide comprises neodymium oxide and cerium oxide, and the mass ratio of neodymium oxide to cerium oxide is 1:1; The content of the rare earth metal oxide in the wear-resistant polished glaze material is 1.0 wt%; Based on the total weight of the frit, the preparation raw materials of the frit comprise the following components: 10-18 parts of potassium feldspar, 2-5 parts of raw talc, 2-4 parts of wollastonite, 8-10 parts of quartz powder, 8-10 parts of calcite, 5-8 parts of alumina, 1-3 parts of zinc oxide, 0.5-0.8 part of yttrium carbonate and 0.8-1.5 part of lanthanum carbonate.

2. The wear-resistant polished glazed tile according to claim 1, characterized in that, In the frit, the mass ratio of zinc oxide, wollastonite, yttrium carbonate and lanthanum carbonate is (3-5):(5-8):1:(1-3).

3. The wear-resistant polished glaze tile according to claim 1, characterized in that The preparation raw materials of the frit further comprise 0.2-0.8 part of manganese carbonate.

4. The wear-resistant polished glazed tile according to claim 1 or 2, characterized in that The thickness of the wear-resistant polished glaze layer is 0.1-0.3 mm.

5. A method for preparing the wear-resistant polished glazed tile according to any one of claims 1-4, characterized in that, The method comprises the following steps: S1, applying a bottom glaze material on the surface of the body to form a bottom glaze layer; S2, mixing the raw materials for preparing the wear-resistant polished glaze material in proportion and then performing ball milling to obtain the wear-resistant polished glaze material; S3, applying the wear-resistant polished glaze material on the surface of the bottom glaze layer to form a wear-resistant polished glaze layer; S4, sintering and polishing the body with the wear-resistant polished glaze layer applied thereon to obtain the wear-resistant polished glaze tile.

6. The preparation method of the wear-resistant polished glazed tile according to claim 5, wherein, The temperature of the sintering is 1100-1250 °C, and the time is 1-2 h.

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