A ceramic tile and its preparation method

Abstract

This application provides a ceramic slab and its preparation method, relating to the field of architectural ceramics production technology. The ceramic slab includes a body layer, a base glaze layer, and a top glaze layer. The raw materials for the body layer, by mass percentage (100%), include: 5%-10% limestone, 2%-8% wollastonite, 1%-5% black talc, 5%-10% white clay, 5%-10% black clay, 5%-10% bentonite, 25%-35% medium-temperature sand, 20%-30% high-temperature sand, and 10%-15% ceramic waste. The preparation method includes: ball milling the raw materials for the body layer into a slurry, spray granulation, pressing to form a body, and bisque firing to obtain a bisque; polishing the surface of the bisque, then sequentially applying the base glaze and top glaze, and firing in a kiln to obtain the ceramic slab. This application, by adjusting the body formula, lowers the bisque firing temperature, reduces the water absorption rate of the bisque, and increases the strength of the body, thereby preparing a ceramic slab with low water absorption and high strength.

Description

Technical Field

[0001] This application relates to the field of building ceramics production technology, and in particular to a ceramic tile and its preparation method. Background Technology

[0002] Porcelain tiles refer to porcelain tiles with a glazed surface. They are mostly made through a double-firing process: a high-temperature bisque firing and a low-temperature glaze firing. The water absorption rate of finished porcelain tiles is generally 16%-19%. For most porcelain tiles, the glaze thickness is generally thicker than that of other tiles. This is mainly because porcelain tiles are often used for wall coverings in kitchens and bathrooms, requiring a thicker glaze for stain resistance. However, a thicker glaze results in lower internal strength after firing, and if the glaze and body are not well matched, cracking is likely to occur later. Furthermore, because porcelain tiles have a relatively high water absorption rate, they are prone to cracking after absorbing moisture and expanding.

[0003] Therefore, there is an urgent need to develop a new type of ceramic tile to solve the problems existing in current ceramic tiles, such as excessively thick glaze, low strength, high water absorption, and susceptibility to cracking. Summary of the Invention

[0004] The purpose of this application is to provide a ceramic tile and its preparation method. By adjusting the raw material formula of the body, the firing temperature of the body is reduced, thereby reducing the water absorption rate of the bisque, ensuring that the glaze can dry quickly, reducing the amount of glaze applied, and still ensuring the smoothness of the glaze surface.

[0005] To achieve the above objectives, the technical solution of this application is as follows:

[0006] This application provides a ceramic tile, comprising a body layer, a base glaze layer, and a top glaze layer;

[0007] The raw materials for the green body layer, by mass percentage (100%), include: limestone 5%-10%, wollastonite 2%-8%, black talc 1%-5%, white clay 5%-10%, black clay 5%-10%, bentonite 5%-10%, medium-temperature sand 25%-35%, high-temperature sand 20%-30%, and ceramic waste 10%-15%.

[0008] Preferably, the raw materials of the green body layer further include a degumming agent, the mass of which is 0.5%-1% of the total mass of the raw materials of the green body layer.

[0009] Preferably, the chemical composition of the green body layer, based on 100% by mass, includes: SiO2 60%-66%, Al2O3 15.5%-16.5%, Fe2O3 2%-2.5%, CaO 6%-8%, MgO 0.7%-1.2%, K2O 2%-3%, Na2O ≤1%, TiO2 ≤0.8%, and loss on ignition 6%-9%.

[0010] Preferably, the chemical composition of the base glaze layer, based on a mass percentage of 100%, includes: SiO2 53%-63%, Al2O3 5%-10%, Fe2O3 0.1%-0.5%, CaO 10%-15%, MgO 1%-3%, K2O 3%-5%, Na2O 0.5%-1%, TiO2 0.01%-0.03%, ZrO2 1%-3%, ZnO 4%-6%, and loss on ignition 1%-2%.

[0011] The chemical composition of the surface glaze layer, by mass percentage (100%), includes: SiO2 53%-63%, Al2O3 5%-10%, Fe2O3 0.1%-0.5%, CaO 10%-15%, MgO 1%-3%, K2O 3%-5%, Na2O 0.5%-1%, TiO2 0.01%-0.03%, ZrO2 1%-3%, ZnO 4%-6%, with a loss on ignition of 1%-2%. Preferably, the thickness of the body layer is 8.9mm-9.4mm, the thickness of the base glaze layer is 0.08mm-0.12mm, and the thickness of the surface glaze layer is 0.12mm-0.2mm.

[0012] This application also provides a method for preparing the above-mentioned ceramic shards, comprising:

[0013] The raw materials of the green body layer are ball-milled into a slurry, spray-granulated, pressed into a green body, and then bisque-fired to obtain a green body.

[0014] The surface of the unglazed blank is polished, and then a base glaze and a top glaze are applied in sequence before firing in a kiln to obtain the porcelain shard.

[0015] Preferably, the ball milling pulping includes: pre-milling the raw material of the green body layer for 8-10 hours, detecting the fineness of the pulp, and if the fineness is 3.1%-3.7%, stopping the ball milling, and then discharging the pulp, removing iron, sieving, and aging; if the fineness exceeds 3.7%, continuing the ball milling.

[0016] Preferably, the preparation method satisfies at least one of the following conditions:

[0017] a. The specific gravity of the slurry obtained by ball milling is 1.68-1.70;

[0018] b. The adhesive used in the pressing mold has a hardness of 93A-95A and an adhesive thickness of ≤1mm;

[0019] c. The press pressure used for the pressing is 28000kN-32000kN;

[0020] d. The thickness of the pressed blank is 8.9mm-9.4mm;

[0021] e. The application methods of the base glaze and the top glaze include at least one of spraying and pouring.

[0022] f. The amount of the base glaze slurry applied is 50g-55g for a 250mm*330mm tray;

[0023] g. The amount of the glaze slurry applied is 68g-70g for a 250mm*330mm tray;

[0024] h. After the surface glaze is applied, a printing process is also included, wherein the printing process includes at least one of the following: decal, screen printing, roller printing, and inkjet printing.

[0025] Preferably, the bisque firing temperature is 1000℃-1020℃ and the time is 28min-32min;

[0026] The firing temperature in the kiln is 1010℃-1020℃, and the firing time is 29min-33min.

[0027] Preferably, after the firing in the kiln is completed, the process further includes: polishing, edge grinding, sorting, and packaging for storage.

[0028] The beneficial effects of this application are:

[0029] The ceramic shards of this application improve the strength of the body by adjusting the raw materials of the body layer, especially by increasing the content of magnesium-containing substances and reducing the amount of calcium-containing substances, thereby lowering the bisque firing temperature of the body and reducing the water absorption rate of the body layer. At the same time, it can also increase the drying speed of the glaze, thereby reducing the water absorption rate of the finished ceramic shards, increasing the strength of the ceramic shards, and greatly reducing the risk of cracking in the later stage.

[0030] The method for preparing ceramic tiles in this application is simple, has a short firing cycle, and high production efficiency, making it suitable for large-scale production. Detailed Implementation

[0031] As used in this article:

[0032] "Prepared from" is synonymous with "comprising". The terms "comprising", "including", "having", "containing", or any other variations thereof as used herein are intended to cover non-exclusive inclusion. For example, a composition, step, method, article, or apparatus that includes the listed elements is not necessarily limited to those elements, but may include other elements not expressly listed or elements inherent to such a composition, step, method, article, or apparatus. The conjunction "composed of" excludes any unnamed elements, steps, or components.

[0033] When a quantity, concentration, or other value or parameter is expressed as a range, a preferred range, or a range defined by a series of upper and lower preferred values, this should be understood as specifically disclosing all ranges formed by any pair of any upper or preferred value with any lower or preferred value, regardless of whether the range is disclosed individually. For example, when the range “1–5” is disclosed, the described range should be interpreted as including ranges “1–4”, “1–3”, “1–2”, “1–2 and 4–5”, “1–3 and 5”, etc. When numerical ranges are described herein, unless otherwise stated, the range is intended to include its endpoints and all integers and fractions within that range.

[0034] In these embodiments, unless otherwise specified, the portions and percentages are all by weight.

[0035] "Parts by mass" refers to the basic unit of measurement that expresses the mass ratio of multiple components. One part can represent any unit mass, such as 1g or 2.689g. If we say that component A has "a" parts by mass and component B has "b" parts by mass, it means the ratio of the mass of component A to the mass of component B is a:b. Alternatively, it can mean that the mass of component A is aK and the mass of component B is bK (K is any number representing a multiplier). It is important to understand that, unlike the number of parts by mass, the sum of the mass parts of all components is not limited to 100 parts.

[0036] "And / or" is used to indicate that one or both of the described situations may occur, for example, A and / or B includes (A and B) and (A or B).

[0037] In response to the aforementioned problems of ordinary ceramic tiles, such as thick glaze, low strength, high water absorption, and susceptibility to later cracking, the inventors of this application have adjusted the formula of the ceramic tile body layer. After repeated experiments and data comparison and analysis, a ceramic tile with low water absorption and fast glaze drying rate has been prepared.

[0038] The ceramic tile of this application comprises a body layer, a base glaze layer, and a top glaze layer. The raw materials of the body layer, by weight percentage (100%), include: limestone 5%-10%, for example, any value between 5% and 10% (e.g., 5%, 6%, 7%, 8%, 9%, 10%); wollastonite 2%-8%, for example, any value between 2% and 8% (e.g., 2%, 3%, 4%, 5%, 6%, 7%, 8%); black talc 1%-5%, for example, any value between 1% and 5% (e.g., 1%, 2%, 3%, 4%, 5%); white clay 5%-10%, for example, any value between 5% and 10% (e.g., 5%, 6%, 7%, 8%, 9%, 10%); and black clay 5%-10%, for example, 5%, 6%, 7%, 8%. 9%, 10%, or any value between 5% and 10%; bentonite 5%-10%, for example, it can be 5%, 6%, 7%, 8%, 9%, 10%, or any value between 5% and 10%; medium-temperature sand 25%-35%, for example, it can be 25%, 27%, 28%, 30%, 32%, 35%, or any value between 25% and 35%; high-temperature sand 20%-30%, for example, it can be 20%, 22%, 23%, 25%, 28%, 30%, or any value between 20% and 30%; ceramic waste 10%-15%, for example, it can be 10%, 11%, 12%, 13%, 14%, 15%, or any value between 10% and 15%.

[0039] In a preferred embodiment of this application, the raw material of the green body layer further includes a desiccant, wherein the mass of the desiccant is 0.5%-1% of the total mass of the raw material of the green body layer, for example, it can be 0.5%, 0.6%, 0.7%, 0.8%, 0.9%, 1% or any value between 0.5% and 1%.

[0040] In a preferred embodiment of this application, the chemical composition of the blank layer, based on a 100% mass percentage, includes: SiO2 60%-66%, for example, it can be any value between 60%, 61%, 62%, 63%, 64%, 65%, 66%, or 60%-66%; Al2O3 15.5%-16.5%, for example, it can be any value between 15.5%, 15.8%, 16%, 16.2%, 16.5%, or 15.5%-16.5%; Fe2O3 2%-2.5%, for example, it can be any value between 2%, 2.1%, 2.2%, 2.3%, 2.4%, 2.5%, or 2%-2.5%; CaO 6%-8%, for example, it can be 6%, 6.5%, 7%. 7.5%, 8%, or any value between 6% and 8%; MgO 0.7%-1.2%, for example, it can be 0.7%, 0.8%, 0.9%, 1.0%, 1.1%, 1.2%, or any value between 0.7% and 1.2%; K2O 2%-3%, for example, it can be 2%, 2.2%, 2.4%, 2.6%, 2.8%, 3%, or any value between 2% and 3%; Na2O ≤1%, for example, it can be 0.1%, 0.3%, 0.5%, 0.7%, 0.9%, 1%, or any value between 0% and 1%; TiO2 ≤0.8%, for example, it can be 0.1%, 0.3%, 0.5%, 0.7%, 10.8%, or any value between 0% and 0.8%; loss on ignition 6%-9%.

[0041] In a preferred embodiment of this application, the chemical composition of the base glaze layer, based on a 100% mass percentage, includes: SiO2 53%-63%, Al2O3 5%-10%, Fe2O3 0.1%-0.5%, CaO 10%-15%, MgO 1%-3%, K2O 3%-5%, Na2O 0.5%-1%, TiO2 0.01%-0.03%, ZrO2 1%-3%, ZnO 4%-6%, and a loss on ignition of 1%-2%.

[0042] It should be noted that the glaze raw material formulas used in the base glaze layer and the top glaze layer of this application are basically the same, so the chemical composition of the base glaze layer and the top glaze layer after firing is also basically the same.

[0043] In a preferred embodiment of this application, the thickness of the body layer is 8.9mm-9.4mm, for example, it can be 8.9mm, 9mm, 9.1mm, 9.2mm, 9.3mm, 9.4mm or any value between 8.9mm and 9.4mm; the thickness of the base glaze layer is 0.08mm-0.12mm, for example, it can be 0.08mm, 0.09mm, 0.1mm, 0.11mm, 0.12mm or any value between 0.08mm and 0.12mm; and the thickness of the top glaze layer is 0.12mm-0.2mm, for example, it can be 0.12mm, 0.14mm, 0.15mm, 0.18mm, 0.2mm or any value between 0.12mm and 0.2mm.

[0044] This application also provides a method for preparing the above-mentioned ceramic shards, including:

[0045] S1. The raw material of the green body layer is ball-milled into a slurry, spray-granulated, pressed into a green body, and then sintered to obtain a green body.

[0046] S2. Polish the surface of the unglazed blank, then apply the base glaze and the top glaze in sequence, and fire it in the kiln to obtain the porcelain slab.

[0047] In a preferred embodiment of this application, ball milling in S1 includes: pre-grinding the raw material of the green body layer for 8-10 hours, and then testing whether the fineness of the slurry is qualified. If the fineness of the slurry is between 3.1% and 3.7% after passing through a 250-mesh sieve, the fineness is qualified, and ball milling can be stopped, followed by slurry discharge, iron removal, sieving, and aging. If the fineness of the slurry exceeds 3.7% after testing, ball milling continues until the fineness test is qualified.

[0048] In a preferred embodiment of this application, the specific gravity of the slurry obtained by ball milling in S1 is 1.68-1.70, for example, it can be 1.68, 1.68, 1.70 or any value between 1.68 and 1.70.

[0049] In a preferred embodiment of this application, when pressing to form a blank in S1, the adhesive hardness of the pressing mold is 93A-95A and the adhesive thickness is ≤1mm.

[0050] In a preferred embodiment of this application, when pressing is performed in S1, the press pressure used is 28000kN-32000kN, for example, it can be 28000kN, 29000kN, 30000kN, 31000kN, 32000kN or any value between 28000kN-32000kN, more preferably 30000kN-32000kN.

[0051] The thickness of the pressed blank is 8.9mm-9.4mm, for example, it can be 8.9mm, 9.0mm, 9.1mm, 9.2mm, 9.3mm, 9.4mm or any value between 8.9mm and 9.4mm.

[0052] Understandably, if the adhesive layer in the mold is too thick and lacks sufficient hardness, it will affect the flatness of the pressed blank, potentially leading to an uneven surface. This, in turn, will affect the application of the subsequent glaze and the condition of the glaze. Therefore, selecting a suitable pressing mold and pressing pressure can ensure the uniformity and flatness of the blank.

[0053] In a preferred embodiment of this application, the application method of the base glaze slurry and the top glaze slurry in S2 includes at least one of spraying and pouring glaze, more preferably pouring glaze.

[0054] Optionally, the amount of base glaze slurry applied is 50g-55g for a 250mm*330mm tray, for example, it can be any value between 50g, 51g, 52g, 53g, 54g, 55g or 50g-55g.

[0055] Optionally, the amount of glaze applied to the surface is 68g-70g for a 250mm*330mm tray, for example, it can be any value between 68g, 69g, 70g or 68g-70g.

[0056] In a preferred embodiment of this application, after the surface glaze application in S2 is completed, a printing process is further included, wherein the printing process includes at least one of the following: decal, screen printing, roller printing, and inkjet printing.

[0057] In a preferred embodiment of this application, after firing in the kiln in step S2, the process further includes polishing, edge grinding, sorting, and packaging for storage.

[0058] In a preferred embodiment of this application, the bisquer firing temperature in S1 is 1000℃-1020℃, for example, it can be 1000℃, 1005℃, 1010℃, 1015℃, 1020℃ or any value between 1000℃ and 1020℃, and the time is 28min-32min, for example, it can be 28min, 29min, 30min, 31min, 32min or any value between 28min and 32min.

[0059] The firing temperature in S2 is 1010℃-1020℃, for example, it can be 1010℃, 1012℃, 1014℃, 1016℃, 1018℃, 1020℃ or any value between 1010℃ and 1020℃, and the firing time is 29min-33min, for example, it can be 29min, 30min, 31min, 32min, 33min or any value between 29min and 33min.

[0060] It should be noted that for ordinary ceramic slabs, during the two-firing process, the bisque firing temperature is typically 1035℃-1045℃, and the glaze firing temperature is typically 1020℃-1026℃, with each firing lasting approximately 40 minutes. This application, however, adjusts the ligand formula, increasing the magnesium oxide content and decreasing the calcium oxide content, thereby lowering the bisque firing temperature and time. Furthermore, after glazing, the temperature and time for glaze firing are also reduced. Compared to a two-firing process, the ceramic slabs of this application are equivalent to undergoing one and a half firings; therefore, they can also be referred to as one-and-a-half-fired ceramic slabs.

[0061] More specifically, the ceramic tile manufacturing process of this application includes:

[0062] (1) Determine the raw material formula for the billet;

[0063] (2) Feeding: Weigh the raw materials according to the names and weights on the formula and feed them accurately;

[0064] (3) Ball milling pulping: After all the raw materials are added, cover the ball, set the time for ball milling, and after the ball milling stops, open the cover to check whether the fineness of the pulp is qualified. If the fineness is qualified, the ball can be discharged directly, and then the pulp is discharged, iron is removed, sieved, and aged; if the fineness is not qualified, the grinding is continued according to the test results until the fineness of the pulp is qualified.

[0065] (4) Spray granulation: The aged and uniform slurry is fed into the spray drying tower for spray drying to form granular powder;

[0066] (5) Pressing: The granular powder formed by spray drying is fed into the press for stamping and forming.

[0067] (6) Biscuit firing: The green body formed by the press is sent into the biscuit firing kiln for biscuit firing to obtain the biscuit green body;

[0068] (7) Store the unglazed blanks after they come out of the kiln in the storage area to facilitate subsequent glazing and firing.

[0069] (8) Polish the bisque-fired body, spray water on the surface of the body, then apply the base glaze and top glaze, and then print on the top glaze layer.

[0070] (9) Dry the glaze layer and, after the moisture content has decreased, send it into the glaze firing kiln for glaze firing.

[0071] (10) Polish, grind, and sort the glazed products to obtain finished porcelain pieces, which are then packaged and stored.

[0072] The implementation schemes of this application will be described in detail below with reference to specific embodiments. However, those skilled in the art will understand that the following embodiments are only for illustrating this application and should not be regarded as limiting the scope of this application. Unless otherwise specified in the embodiments, conventional conditions or conditions recommended by the manufacturer shall apply. Reagents or instruments used without specified manufacturers are all conventional products that can be purchased commercially.

[0073] Example 1

[0074] This embodiment provides a ceramic tile, the specific preparation method of which includes:

[0075] (1) Determine the raw material formula of the green body, which includes 5 kg of limestone, 5 kg of wollastonite, 5 kg of black talc, 7 kg of white clay, 7.5 kg of black clay, 10 kg of bentonite, 30 kg of medium-temperature sand, 20 kg of high-temperature sand, 10 kg of ceramic waste, and 0.5 kg of descaling agent by mass.

[0076] (2) Feeding: Weigh the raw materials according to the name and weight of the green body on the formula and feed them accurately;

[0077] (3) Ball milling: After all raw materials are added, cover the ball mill and set it to 9 hours for pre-grinding. After the ball milling stops, open the cover to check whether the ball milling fineness of the slurry is qualified. If the fineness is between 3.1% and 3.7%, the ball mill can be discharged directly, and then the slurry can be discharged, iron removed, sieved, and aged. If the fineness is greater than 3.7%, ball milling needs to be continued until the fineness of the slurry is qualified.

[0078] (4) Spray granulation: The aged and uniform slurry is fed into the spray drying tower for spray drying to form granular powder;

[0079] (5) Pressing: The granular powder formed by spray drying is fed into a press for stamping to obtain a blank with a thickness of 9.0 mm;

[0080] (6) Bismuth firing: The green body formed by the press is sent into the bismuth firing kiln for bismuth firing. The bismuth firing temperature is 1000℃ and the time is 32min to obtain the green body. The chemical composition of the green body layer after bismuth firing is: SiO2 60%, Al2O3 16%, Fe2O3 2.1%, CaO 7.0%, MgO 1.1%, K2O 2.3%, Na2O 0.5%, TiO2 0.7%, and loss on ignition 9.0%.

[0081] (7) Store the unglazed billets after they have exited the kiln in a storage area with a floor area of ​​up to 35,000 m². 2 ;

[0082] (8) Polish the unglazed blank, then spray water on the surface of the blank, and then apply the base glaze and the top glaze in sequence. The specific gravity of the base glaze is between 1.8 and 1.84, and the amount of glaze applied is 50g (250mm*330mm tray). The specific gravity of the top glaze is between 1.74 and 1.76, and the amount of glaze applied is 70g (250mm*330mm tray). Then, print on the top glaze.

[0083] (9) After drying the printed glaze layer, it is sent to the glaze firing kiln for glaze firing at a temperature of 1020℃ for 30 minutes.

[0084] (10) Polish, grind, and sort the glazed products to obtain finished porcelain pieces, and then package and store them.

[0085] Example 2

[0086] This embodiment provides a ceramic tile, and the specific preparation method is the same as in Embodiment 1, except that:

[0087] The raw material formula for step (1) includes: 10kg limestone, 2kg wollastonite, 1kg black talc, 5kg white clay, 5kg black clay, 6.5kg bentonite, 35kg medium-temperature sand, 25kg high-temperature sand, 10kg ceramic waste, and 0.5kg descaling agent.

[0088] The sintering temperature in step (6) was 1010℃ and the time was 29 min. The chemical composition of the sintered green body layer was: SiO2 61.5%, Al2O3 15.9%, Fe2O3 2.1%, CaO 7.05%, MgO 1.1%, K2O 2.1%, Na2O 0.45%, TiO2 0.8%, and loss on ignition 9%.

[0089] Example 3

[0090] This embodiment provides a ceramic tile, and the specific preparation method is the same as in Embodiment 1, except that:

[0091] The raw material formula for step (1) includes: 7kg limestone, 3kg wollastonite, 4kg black talc, 10kg white clay, 10kg black clay, 5kg bentonite, 25kg medium-temperature sand, 20kg high-temperature sand, 15kg ceramic waste, and 1kg descaling agent.

[0092] The sintering temperature in step (6) was 1020℃ and the time was 28 min. The chemical composition of the sintered green body layer was: SiO2 61.2%, Al2O3 16.3%, Fe2O3 2.2%, CaO 6.9%, MgO 0.9%, K2O 2.4%, Na2O 0.4%, TiO2 0.8%, and loss on ignition 8.9%.

[0093] Comparative Example 1

[0094] This comparative example provides a common ceramic tile, prepared using the same method as in Example 1, except that:

[0095] The raw material formula for step (1) includes: 5.5 kg of wollastonite, 8.5 kg of limestone, 6.5 kg of white clay, 4.5 kg of black clay, 4 kg of bentonite, 15 kg of medium-temperature sand, 18 kg of high-temperature sand, 14 kg of medium-high temperature sand, 12 kg of ceramic waste, 9 kg of porcelain clay, and 0.5 kg of descaling agent.

[0096] The sintering temperature in step (6) was 1040℃ and the time was 38 min. The chemical composition of the sintered green body layer was: SiO2 61%, Al2O3 15.5%, Fe2O3 2.3%, CaO 8.9%, MgO 0.6%, K2O 2.4%, Na2O 0.5%, TiO2 0.8%, and loss on ignition 9.3%.

[0097] The glazing temperature in step (9) is 1025℃ and the time is 45min.

[0098] Comparative Example 2

[0099] This comparative example provides a ceramic tile, prepared using the same method as in Example 1, except that:

[0100] The firing temperature in step (6) is 980℃ and the firing time is 30min.

[0101] The rupture modulus of the unglazed body, water absorption rate of the unglazed body, glaze drying speed, rupture modulus of the finished ceramic shards, and water absorption rate of the finished ceramic shards were tested for Examples 1-3 and Comparative Examples 1-2. The test results are shown in Table 1.

[0102] Table 1. Test results of unglazed and finished ceramic pieces prepared in Examples 1-3 and Comparative Examples 1-2.

[0103]

[0104] As can be seen from Table 1, compared with the ordinary porcelain shards prepared by the two-firing process in Comparative Example 1, the bisques prepared in Examples 1 and 3 of this application have lower water absorption rates, faster glaze drying speeds, and lower water absorption rates in the finished porcelain shards. In Example 2, although the water absorption rate does not change much, the glaze drying speed is significantly shorter, which is beneficial to improving production efficiency. In Comparative Example 2, the lower bisque firing temperature leads to incomplete reaction of substances in the bisque, resulting in higher water absorption rates and slower glaze drying speeds in the bisque.

[0105] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

[0106] Furthermore, those skilled in the art will understand that although some embodiments herein include certain features included in other embodiments but not others, combinations of features from different embodiments are intended to be within the scope of this application and form different embodiments. For example, any of the embodiments claimed above can be used in any combination. The information disclosed in this background section is intended only to enhance the understanding of the general background of this application and should not be construed as an admission or in any way implying that such information constitutes prior art known to those skilled in the art.

Claims

1. A type of ceramic tile, characterized in that, It includes the body layer, the base glaze layer, and the top glaze layer; The raw materials for the green body layer, by weight percentage (100%), include: 5%-10% limestone, 2%-8% wollastonite, 1%-5% black talc, 5%-10% white clay, 5%-10% black clay, 5%-10% bentonite, 25%-35% medium-temperature sand, 20%-30% high-temperature sand, and 10%-15% ceramic waste. The chemical composition of the green body layer, based on a mass percentage of 100%, includes: SiO2 60%-66%, Al2O3 15.5%-16.5%, Fe2O3 2%-2.5%, CaO 6%-8%, MgO 0.7%-1.2%, K2O 2%-3%, Na2O ≤1%, TiO2 ≤0.8%, and loss on ignition 6%-9%; The chemical composition of the base glaze layer, by mass percentage (100%), includes: SiO2 53%-63%, Al2O3 5%-10%, Fe2O3 0.1%-0.5%, CaO 10%-15%, MgO 1%-3%, K2O 3%-5%, Na2O 0.5%-1%, TiO2 0.01%-0.03%, ZrO2 1%-3%, ZnO 4%-6%, with a loss on ignition of 1%-2%. The chemical composition of the surface glaze layer, by mass percentage (100%), includes: SiO2 53%-63%, Al2O3 5%-10%, Fe2O3 0.1%-0.5%, CaO 10%-15%, MgO 1%-3%, K2O 3%-5%, Na2O 0.5%-1%, TiO2 0.01%-0.03%, ZrO2 1%-3%, ZnO 4%-6%, and loss on ignition 1%-2%.

2. The ceramic tile as described in claim 1, characterized in that, The raw materials of the green body layer also include a degumming agent, the mass of which is 0.5%-1% of the total mass of the raw materials of the green body layer.

3. The ceramic tile as described in claim 1 or 2, characterized in that, The thickness of the body layer is 8.9mm-9.4mm, the thickness of the base glaze layer is 0.08mm-0.12mm, and the thickness of the top glaze layer is 0.12mm-0.2mm.

4. A method for preparing ceramic tiles as described in any one of claims 1-3, characterized in that, include: The raw materials of the green body layer are ball-milled into a slurry, spray-granulated, pressed into a green body, and then bisque-fired to obtain a green body. The surface of the unglazed blank is polished, and then a base glaze and a top glaze are applied in sequence. The blank is then fired in a kiln to obtain the porcelain shard. The bisque firing temperature is 1000℃-1020℃, and the time is 28min-32min; The firing temperature in the kiln is 1010℃-1020℃, and the firing time is 29min-33min.

5. The preparation method according to claim 4, characterized in that, The ball milling pulping process includes: The raw materials of the green body layer are pre-ground for 8-10 hours, and the fineness of the slurry is tested. If the fineness is 3.1%-3.7%, ball milling is stopped, and the slurry is discharged, iron is removed, sieved, and aged. If the fineness exceeds 3.7%, ball milling is continued.

6. The preparation method according to claim 4, characterized in that, At least one of the following conditions must be met: a. The specific gravity of the slurry obtained by ball milling is 1.68-1.70; b. The adhesive hardness of the pressing mold used for pressing is 93A-95A, and the adhesive thickness is ≤1mm; c. The press pressure used for the pressing is 28000kN-32000kN; d. The thickness of the pressed blank is 8.9mm-9.4mm; e. The application methods of the base glaze and the top glaze include at least one of spraying and pouring. f. The amount of the base glaze slurry applied is 50g-55g for a 250mm*330mm tray; g. The amount of the glaze slurry applied is 68g-70g for a 250mm*330mm tray; h. After the surface glaze is applied, a printing process is also included, wherein the printing process includes at least one of the following: decal, screen printing, roller printing, and inkjet printing.

7. The preparation method according to any one of claims 4-6, characterized in that, After the firing process in the kiln is completed, the process also includes polishing, edge grinding, sorting, packaging, and warehousing.

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