A correction conversion method for color glaze net color brick experiment and production

Abstract

This invention relates to a correction and conversion method for the experiment and production of solid-color glazed bricks, comprising: (1) calculating the glaze amount of the brick blank according to the glaze specific gravity, glaze amount, and standard glaze area; (2) obtaining a standard color sample A; (3) obtaining a ceramic green body; (4) obtaining a production surface glaze, and adjusting the color by adding inorganic pigments to the standard sample color to obtain a color glaze slurry; (5) injecting the glaze slurry with the adjusted color into a glaze preparation device and applying it to the surface of the green body; (6) drying the glazed green body and firing it in a kiln to obtain an experimental sample B; (7) comparing the color of experimental sample B with that of standard sample A to check whether the color of experimental sample B is qualified; if not, repeat steps 3 to 6 until qualified; (8) according to the qualified experimental sample B, the inorganic pigment scheme, and the glaze amount calculation formula, obtaining the correction formula for the total amount of inorganic pigment glaze added; (9) applying the color glaze with the adjusted pigments, and firing it to obtain a solid-color brick C; (10) systematically checking and comparing whether the color of solid-color brick C is consistent with that of standard sample A; if consistent or within the allowable range of color deviation, then production begins.

Description

Technical Field

[0001] This invention belongs to the field of building ceramic tile technology, and specifically relates to a correction and conversion method for the experiment and production of colored glaze solid color tiles. Background Technology

[0002] In the past two years, the ceramic tile market has seen a significant increase in Morandi-colored tiles, and these tiles are generally larger, exceeding 600mm x 1200mm in area, and even appearing in larger slab ceramic tiles. The so-called Morandi color scheme refers to monochrome, clean, or pure colors with a pure surface and low color saturation. There are two main manufacturing processes for these clean-color tiles: one involves adding one or more inorganic pigments to the base glaze, using multiple pigments in a set ratio to create a composite color; the other uses a digital inkjet printer to combine colors from different channels to achieve the desired color. Both processes have their own advantages and disadvantages.

[0003] Adding inorganic pigments to the base glaze results in more stable colors with smaller color deviations when production is repeated after a longer period, allowing for rapid trial production. However, each trial is cumbersome. Firstly, due to the large size, online testing is not feasible. Each development or trial requires manually creating small samples for comparison. Only when the color of each sample matches or closely resembles the standard sample is online glazing undertaken. After firing, a significant difference often exists between the sample color and the online-glazed product color. This color difference is primarily due to variations in glaze thickness. Changes in glaze thickness alter the pigment content in the glaze, ultimately leading to color variations in the final product.

[0004] The pilot-scale experiment used a standard glaze thickness. However, in actual pilot-scale and production, the amount of glaze or the specific gravity of the glaze slurry is adjusted appropriately based on production requirements such as the presence of glaze defects and the flatness of the fired product. This means increasing or decreasing the amount of glaze and decreasing or increasing the specific gravity of the glaze slurry. Once the amount of glaze or the specific gravity of the glaze slurry changes, the glaze thickness also changes. Whether the glaze thickness is increased or decreased, it ultimately affects the total pigment content per unit area of ​​the product after glazing, thus resulting in a significant difference in color between the actual produced product and the experimental sample. When the actual glaze thickness and specific gravity of the glaze slurry are determined and production conditions are met, these differences from the standard sample's glaze thickness and specific gravity mean that the content of inorganic pigments in the glaze needs to be repeatedly adjusted on the production line to achieve the color depth of the standard sample. This increases workload, affects normal production, and extends delivery time. Secondly, the conditions for each online experiment for large-scale products are limited. More experiments lead to longer delivery cycles, increased experimental costs, and waste of a large amount of experimental products.

[0005] On the other hand, solid-color tiles printed using digital inkjet printers exhibit several issues. Light-colored tiles show visible ink dots of various colors upon close inspection, resulting in less pure colors. Dark-colored tiles are prone to printhead streaks, placing extremely high demands on the equipment. Achieving consistent printing results in subsequent trials is particularly difficult, as product quality relies entirely on the printhead's stability, which is highly limiting. Therefore, most solid-color tiles of the Morandi style are produced by adding inorganic pigments to the base glaze, a time-consuming and labor-intensive process. Although small-scale test samples pass, each online production product shows significant color variations compared to the tested samples, requiring repeated adjustments. Thus, existing technology has shortcomings and needs improvement. It is necessary to identify the factors influencing color changes between small-scale and online production, enabling a rapid and consistent color transition from the tested samples to the actual production. Summary of the Invention

[0006] To address the shortcomings of the existing technology, the purpose of this invention is to provide a method for correcting and converting the color of solid-color bricks produced using colored glaze technology. This method addresses the significant color difference between small-scale trials and online production, enabling rapid conversion and correction between the pigment content of samples that pass the small-scale trials and the pigment content of the production glaze, achieving color consistency between the two.

[0007] The technical solution of this invention is a correction and conversion method for the experiment and production of colored glaze solid color bricks, which is characterized by including the following steps:

[0008] (1) Based on the production of glaze trays with a specific gravity range of 1.75 to 1.86, a glaze application amount of 0.18 m², and a standard glazing area of ​​300 mm * 600 mm, the formula for calculating the glaze application amount per unit standard area of ​​brick blank is derived:

[0009]

[0010] In the formula: h is the glaze thickness in mm; M is the glaze amount in g; d is the glaze density in g / cm³. 3 ;s represents the standard glazing area, in square meters;

[0011] In an Excel spreadsheet, the amount of glaze applied is entered into a row, represented by row i; the density of the glaze paste is entered into a column, represented by column j, where i and j are both positive integers; then equation (1) is expressed as:

[0012]

[0013] (2) Obtain standard color sample A, which refers to the sample provided by the designer or end customer, for future use;

[0014] (3) Obtain ceramic green bodies from the production line and clean the surface dust for later use;

[0015] (4) Obtain the surface glaze for production, add inorganic pigments to the surface glaze according to the color of standard color sample A, and prepare the color glaze slurry for later use;

[0016] (5) Place the experimental glaze preparation device at one end of the ceramic green body surface; pour the prepared color glaze slurry into the glaze preparation device; hold the edges of both ends of the glaze preparation device firmly with both hands, and pull the glaze preparation device to the other end of the green body parallel to the green body surface to apply the color glaze slurry to the green body surface;

[0017] (6) After drying the glazed body, it was fired in the production kiln to obtain experimental sample B;

[0018] (7) Compare the color of experimental sample B with that of standard sample A. Use a colorimeter to detect the change in Lab value of the sample, calculate whether ΔE between the two is within the range, and confirm whether the color of experimental sample B is qualified. If experimental sample B is unqualified, repeat steps (3) to (6) until the experimental sample is qualified.

[0019] (8) Based on the qualified experimental sample B and the inorganic pigment scheme, and combined with the calculation formula for the amount of glaze applied in step (1), obtain the correction formula for the total amount of inorganic pigment glaze added:

[0020] Right now:

[0021] Where: m is the amount of corrective pigment used in the glaze, in g; h0 is the glaze thickness of the qualified sample, in mm; h is the actual glaze thickness obtained by formula (1), in mm; m0 is the amount of pigment added to the qualified sample, in g;

[0022] In the Excel spreadsheet, the amount of glaze applied is entered into a row, represented by row i; the proportion of glaze applied is entered into a column, represented by column j, where i and j are both positive integers; then equation (2) is expressed as:

[0023]

[0024] (9) Apply the prepared color glaze with the corrected amount of pigment to the production line, and after firing, obtain plain color brick C;

[0025] (10) Use a colorimeter to detect the change in the Lab value of the sample, calculate whether the ΔE between samples C and A is within the range, and determine whether the colors are consistent. If they are consistent or within the allowable range of color deviation, then produce according to this scheme.

[0026] As a preferred embodiment, step (1) further includes: within the parameter range used in the glazing process, using Excel software, inputting the glaze slurry specific gravity d, glaze application amount m, and unit glazing area s in the corresponding cells, and automatically generating a glaze amount and thickness conversion table according to formula (1); the glaze amount and thickness conversion table contains commonly used combinations of glaze application amount and glaze specific gravity as well as the corresponding glaze layer thickness, and the glaze slurry application thickness with the corresponding specific gravity and glaze amount can be quickly found according to the glaze amount and thickness conversion table.

[0027] Preferably: In step (1), when the production specific gravity remains constant and the glaze amount needs to be adjusted to regulate product performance, the product will experience color deviation due to changes in the glaze amount. In this case, refer to the correction amount conversion table to find the correction amount value corresponding to the adjusted glaze amount, and quickly adjust accordingly to avoid or reduce color differences caused by adjusting the glaze amount. Specifically, this includes: if the glaze amount needs to be increased or decreased due to product requirements, with the glaze amount increasing from X to Y, or decreasing from X to Z, refer to the correction amount conversion table to find the intersecting cell for the specific gravity corresponding to the Y glaze amount. Alternatively, find the intersecting cell corresponding to the specific gravity and the Z glaze amount, and change the additional pigment correction amount from a to b; or change the pigment correction amount from c to d; if the production glaze has not yet been prepared, add pigment directly according to the correction amount b, or directly according to the correction amount d; if the production glaze has been adjusted according to the original correction amount a, add a set amount of white glaze with the same specific gravity to the glaze to correct the color deviation caused by the increase in glaze amount through calculation; or if the production glaze has been prepared, add pigment to the glaze to correct the color deviation caused by the reduction in glaze amount.

[0028] Preferably, in step (1), when the amount of glaze applied remains constant but the specific gravity of the glaze needs to be adjusted to regulate the performance of the glaze slurry, if the amount of glaze applied remains constant and the specific gravity of the glaze slurry is increased, the glaze thickness will gradually decrease as the specific gravity increases. At this time, the total amount of added pigment in the glaze slurry will also decrease, resulting in a gradual lightening of the color on the product. Conversely, if the amount of glaze applied remains constant and the specific gravity of the glaze slurry is decreased, the glaze thickness will gradually increase as the specific gravity decreases, resulting in a gradual darkening of the color on the product. By referring to the correction amount conversion table, the correction amount value of the corresponding cell after adjusting the specific gravity while keeping the amount of glaze constant can be found. The total amount of added pigment is quickly adjusted based on the numerical values ​​to avoid and reduce color differences caused by adjusting the glaze slurry specific gravity. Specifically, if the glaze slurry specific gravity needs to be increased from A to B due to glazing performance requirements, refer to the correction amount conversion table to find the cell corresponding to the two specific gravity values ​​for the X glaze amount, and increase the added correction pigment from a to b. If the production glaze slurry has not yet been prepared, the color glaze slurry is directly prepared according to the correction amount b. If the production glaze slurry has already been prepared, the specific gravity of the prepared glaze slurry needs to be adjusted to the required specific gravity, and then the difference in pigment between the two values ​​is added to the unit glaze slurry.

[0029] As a preferred option: step (4) further includes: adding inorganic pigment to the glaze according to the color of standard color sample A means weighing 1 part of production glaze slurry and 1 part of color-matching inorganic pigment, and mixing 1 part of inorganic pigment with 1 part of mass production glaze slurry evenly to prepare a colored glaze slurry for the experiment.

[0030] As a preferred option: In step (4), inorganic pigments are added to the glaze to adjust the color according to the standard color sample A, specifically one of the following:

[0031] (4.1) Weigh 150g of production glaze slurry with a specific gravity of 1.78 and 0.63g of inorganic pigment, and mix the inorganic pigment with 150g of production glaze slurry evenly.

[0032] (4.2) Weigh 100g of production glaze slurry with a specific gravity of 1.85 and 100g of inorganic pigment, and mix the inorganic pigment with 100g of production glaze slurry evenly.

[0033] (4.3) Weigh 200g of production glaze with a specific gravity of 1.83 and 1.22g of inorganic pigment, and mix the inorganic pigment with 200g of production glaze evenly.

[0034] As a preferred embodiment: the qualified experimental sample for adding inorganic pigments to the glaze according to the color of standard color sample A in step (4.1) is:

[0035] (4.11) The ratio of each glaze paste to the added inorganic pigment is 150:0.63 = 100:0.42, which means that 0.42g of inorganic pigment needs to be added to 100g of glaze paste with a specific gravity of 1.78.

[0036] The qualified experimental sample for adding inorganic pigments to the glaze according to the color of standard color sample A in step (4.2) is:

[0037] (4.21) The ratio of each glaze paste to the added inorganic pigment is 100:0.72 = 100:0.72, which means that 100g of glaze paste with a specific gravity of 1.85 requires 0.72g of added inorganic pigment.

[0038] The qualified experimental sample for adding inorganic pigments to the glaze according to the color of standard color sample A as described in step (4.3) is:

[0039] (4.31) The ratio of each glaze paste to the added inorganic pigment is 200:1.22 = 100:0.61, which means that 0.61g of inorganic pigment needs to be added to 100g of glaze paste with a specific gravity of 1.83.

[0040] As a preferred option: step (8) includes: continuing to use Excel office software, and combining the calculation formula (1) for the amount of glaze obtained in step (1), first enter the total amount of qualified experimental sample pigment and the glaze thickness parameters added to 100g unit glaze slurry in the corresponding cell, and the software will automatically generate a correction amount conversion table for the total amount of inorganic pigment added required for the production glaze amount; in the correction amount conversion table, quickly and intuitively find the correction amount of added inorganic pigment corresponding to the specific gravity and glaze amount parameters.

[0041] As a preferred embodiment, step (8) further includes: obtaining the pigment correction amount by inputting the glazing amount, specifically selecting one of the following:

[0042] (8.1) Specific gravity 1.78, glaze amount 90g, total colorant 0.42g, the corresponding amount of added pigment correction in the table is 0.449g;

[0043] (8.2) Specific gravity 1.85, glaze amount 86g, total pigment 0.72g, the corresponding amount of added pigment correction in the table is 0.836g;

[0044] (8.3) Specific gravity 1.83, glaze amount 87g, total colorant 0.61g, the corresponding amount of added pigment correction in the table is 0.693g.

[0045] As a preferred option: step (8) further includes: obtaining the corresponding pigment correction amount by reducing the amount of glaze: due to product requirements, the amount of glaze needs to be reduced by 2g, at which point the amount of glaze changes from 87g to 85g. Referring to the correction amount conversion table, find the intersecting cell corresponding to the 85g glaze amount with a specific gravity of 1.83, and the pigment correction amount changes from 0.693g to 0.709g. If the glaze slurry has not yet been prepared, then add pigment directly according to the correction amount of 0.709g. If the glaze slurry has been prepared, then add pigment to the glaze slurry to correct the color deviation caused by the reduction of the amount of glaze.

[0046] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0047] (1) This invention enables the color glaze to be quickly converted between small-scale experiments and production, and the color can be consistent.

[0048] (2) The present invention provides a correction table that can automatically calculate and convert the added inorganic pigments. When the amount of glaze produced or the total amount of added pigments changes, the table can be quickly consulted to obtain the accurate amount of added correction.

[0049] (3) This invention reduces the number of experiments required by process technicians, reduces workload, and shortens delivery time. Attached Figure Description

[0050] Figure 1 This is a correction table for the qualified experimental sample of the present invention when the amount of pigment added is 0.42g in Example 1;

[0051] Figure 2 This is a correction table for the qualified experimental sample of the present invention when the amount of pigment added is 0.72g in Example 2 of the present invention;

[0052] Figure 3 This is a correction table for the qualified experimental sample of the present invention when the amount of pigment added is 0.61g in Example 3;

[0053] Figure 4 This is the table showing the correction of the glaze amount, specific gravity, and added pigments for the qualified experimental sample in Example 1 of this invention.

[0054] Figure 5 This is a correction table for increasing the glaze amount when the pigment addition amount of the qualified experimental sample in Example 2 of the present invention is 0.72g;

[0055] Figure 6 This is a correction table for reducing the amount of glaze when the amount of pigment added to the qualified experimental sample in Example 3 of the present invention is 0.61g;

[0056] Figure 7 This is a flowchart of the color glaze experiment and production process, including the conversion of external pigments for correction.

[0057] Figure 8 This is a production glaze thickness conversion table automatically obtained under the standard glazing plate and standard glazing thickness of the present invention. Detailed Implementation

[0058] The present invention will be further described in detail below with reference to embodiments:

[0059] For the implementation process of this invention, please refer to [link / reference]. Figure 7 As shown.

[0060] A corrective conversion method for the experimentation and production of solid-color glazed tiles includes:

[0061] (1) Based on the production of glaze trays with a specific gravity range of 1.75 to 1.86 and a glaze application amount of 0.18 m², and a standard glazing area of ​​300 mm * 600 mm, using the glazing process, the specific gravity range of the glaze, and the glaze application amount of the standard glaze tray area, the following formula is derived for calculating the glaze application amount per unit standard area of ​​brick:

[0062]

[0063] The specific gravity of the glaze during production is an adjustable variable. Therefore, the specific gravity is adjusted according to needs, such as whether the brick shape is straight or whether there are defects in the glaze. Changes in specific gravity will lead to changes in the color of the product, so it is necessary to correct the amount of glaze applied.

[0064] Within the parameter range used in the glazing process, using Excel software, the amount of glaze applied is entered into a row (represented by row i) and the density of the glaze slurry is entered into a column (represented by column j), where i and j are both positive integers. Then formula (1) is expressed as:

[0065]

[0066] Enter the glaze specific gravity d, glaze application amount m, and unit glaze application area s in the corresponding cells. The formula will automatically generate a conversion table for the thickness h of the production glaze amount. (Refer to the table for details.) Figure 8 The glaze thickness conversion table is automatically generated under standard glazing pan and standard glazing thickness. When the standard glazing pan or standard glazing thickness is changed, the thickness h conversion table for the generated glaze amount can also be automatically generated according to formula (1). The table contains possible combinations of commonly used glaze amounts and glaze specific gravities, as well as the corresponding glaze layer thicknesses. Technicians can quickly find the glaze thickness of the glaze slurry with the corresponding specific gravity and glaze amount based on the table (please refer to...). Figures 1 to 6 (as shown); however, this table does not exhaust all possible combinations of glaze slurry specific gravity and glaze amount;

[0067] (2) Obtain a standard color sample A, wherein the standard color sample A refers to a sample provided by the designer, end customer, etc., which is determined as a standard sample for later use;

[0068] (3) Obtain ceramic green bodies from the production line and clean the surface dust for later use; the present invention uses ceramic green bodies consistent with the production line, and cleaning the surface ensures the quality of glazing;

[0069] All experiments in this invention are conducted using the same glaze slurry used in mass production to avoid experimental errors; however, experimental errors may occur when the glaze slurry used in the experiment differs from that used in mass production.

[0070] Adding pigment to the standard sample means weighing 1 part of mass production glaze paste and 1 part of color-matching inorganic pigment, and mixing 1 part of inorganic pigment with 1 part of mass production glaze paste evenly to prepare a colored glaze paste for the experiment.

[0071] Additional Example 1: Weigh 150g of mass production glaze with a specific gravity of 1.78 and 0.63g of inorganic pigment, and mix the inorganic pigment with 150g of mass production glaze evenly.

[0072] Additional Example 2: Weigh 100g of mass production glaze with a specific gravity of 1.85 and 0.72g of inorganic pigment, and mix the inorganic pigment with 100g of mass production glaze evenly.

[0073] Additional Example 3: Weigh 200g of mass production glaze with a specific gravity of 1.83 and 1.22g of inorganic pigment, and mix the inorganic pigment with 200g of mass production glaze evenly;

[0074] The above examples are only a portion and are not exhaustive.

[0075] (4) Obtain the production glaze, add inorganic pigments to the glaze according to the color of standard sample A, and prepare the colored glaze slurry. Specifically, choose one of the following:

[0076] (4.1) Weigh 150g of production glaze slurry with a specific gravity of 1.78 and 0.63g of inorganic pigment, and mix the inorganic pigment with 150g of production glaze slurry evenly.

[0077] (4.2) Weigh 100g of production glaze slurry with a specific gravity of 1.85 and 100g of inorganic pigment, and mix the inorganic pigment with 100g of production glaze slurry evenly.

[0078] (4.3) Weigh 1 part of 200g of production glaze slurry with a specific gravity of 1.83 and 1 part of inorganic pigment with a specific gravity of 1.22g, and mix the inorganic pigment with 200g of production glaze slurry evenly.

[0079] Step (4) involves adding inorganic pigments to the glaze according to the color of standard color sample A, specifically selecting one of the following:

[0080] (4.11) Qualified test sample: The ratio of each glaze paste to the added inorganic pigment is 150:0.63 = 100:0.42, which means that 100g of glaze paste with a specific gravity of 1.78 requires 0.42g of added inorganic pigment.

[0081] (4.21) Qualified test sample: The ratio of each glaze paste to the added inorganic pigment is 100:0.72 = 100:0.72, which means that 100g of glaze paste with a specific gravity of 1.85 requires 0.72g of added inorganic pigment.

[0082] (4.31) Qualified test sample: The ratio of each glaze paste to added inorganic pigment is 200:1.22 = 100:0.61, which means that 0.61g of inorganic pigment needs to be added to 100g of glaze paste with a specific gravity of 1.83.

[0083] Where: m is the amount of corrective pigment used in the glaze, in g; h0 is the glaze thickness of the qualified sample, in mm; h is the actual glaze thickness obtained by formula (1), in mm; m0 is the amount of pigment added to the qualified sample, in g; In the Excel table, input the glaze amount into the row, represented by row i; input the glaze proportion into the column, represented by column j, where i and j are both positive integers;

[0084] (5) Place the experimental glaze preparation device at one end of the ceramic green body surface; slowly pour the prepared colored glaze slurry into the glaze preparation device; firmly grasp the edges of both ends of the glaze preparation device with both hands, and slowly pull the glaze preparation device to the other end of the green body parallel to the green body surface to apply the colored glaze slurry to the green body surface; regardless of the specific gravity of the glaze slurry, the experimental glaze preparation device can form a fixed glaze layer with a thickness of 0.3 mm on the surface of the ceramic brick body.

[0085] ⑹ After drying the glazed body, it was fired in the production kiln. The product size was 900×2600×9 (mm), the firing time was 90 min, the maximum firing temperature was 1180℃, and the holding time was 5 minutes. Experimental sample B was obtained.

[0086] (7) Compare the color of experimental sample B with that of standard sample A. Use a colorimeter to detect the change in Lab value of the sample, calculate whether ΔE between the two is within the range, and confirm whether the color of experimental sample B is qualified. If experimental sample B is unqualified, repeat steps 3 to 6 until the experimental sample is qualified.

[0087] (8) Based on the inorganic pigment addition scheme for qualified experimental sample B, and combined with the calculation formula for the glaze application amount in step (1), the correction formula for the total amount of added inorganic pigment glaze is obtained:

[0088]

[0089] In the Excel spreadsheet, the amount of glaze applied is entered into a row, represented by row i; the proportion of glaze applied is entered into a column, represented by column j, where i and j are both positive integers; then equation (2) is expressed as:

[0090]

[0091] Where: m is the amount of corrective pigment used in the glaze, in g; h0 is the glaze thickness of the qualified sample, in mm; h is the actual glaze thickness obtained by formula (1), in mm; m0 is the amount of pigment added to the qualified sample, in g; the glaze thickness h is calculated based on the amount of glaze applied and the specific gravity of the glaze during actual production. ij Combined with formula (2) to obtain Figure 2 The corrective scheme for adding inorganic pigments is shown. According to Example 1 of the qualified test sample, the ratio of each glaze slurry to added inorganic pigments is calculated to be 150:0.63 = 100:0.42, which means that 0.42g of inorganic pigments need to be added to 100g of glaze slurry with a specific gravity of 1.78 in mass production.

[0092] Based on Example 2 of the qualified test sample, the ratio of each glaze slurry to the added inorganic pigment is calculated to be 100:0.72 = 100:0.72, which means that 0.72g of inorganic pigment needs to be added to 100g of glaze slurry with a specific gravity of 1.85 in mass production.

[0093] Based on Example 3 of the qualified test sample, the ratio of each glaze slurry to the added inorganic pigment is calculated to be 200:1.22 = 100:0.61, which means that 0.61g of inorganic pigment needs to be added to 100g of glaze slurry with a specific gravity of 1.83 in mass production.

[0094] Continuing to use Excel, and combining the thickness parameters in the table obtained in step (1), first enter the total amount of pigment added to 100g of glaze slurry for the qualified experimental sample and the glaze thickness parameters in the corresponding cells. The software will then automatically generate a correction amount conversion table for the total amount of inorganic pigment required for the production glaze. In the correction amount conversion table, technicians can quickly and intuitively find the corresponding corrective addition amount of inorganic pigment for the specific gravity and glaze amount parameters.

[0095] Please see Figure 1 As shown, based on Example 1 of the qualified experimental sample, the ratio of each glaze slurry to the added inorganic pigment is calculated to be 150:0.63 = 100:0.42, which means that 0.42g of inorganic pigment needs to be added to 100g of glaze slurry with a specific gravity of 1.78 in mass production.

[0096] Please see Figure 2 As shown, based on Example 2 of the qualified experimental sample, the ratio of each glaze slurry to the added inorganic pigment is calculated to be 100:0.72 = 100:0.72, which means that 0.72g of inorganic pigment needs to be added to 100g of glaze slurry with a specific gravity of 1.85 in mass production.

[0097] Please see Figure 3 As shown, based on Example 3 of the qualified experimental sample, the ratio of each glaze slurry to the added inorganic pigment is calculated to be 200:1.22 = 100:0.61, which means that 0.61g of inorganic pigment needs to be added to 100g of glaze slurry with a specific gravity of 1.83 in mass production.

[0098] Please see Figure 4 As shown, continuing to use Excel software, and combining the thickness parameters in the table obtained in step (1), first enter the total amount of qualified experimental sample pigment added to 100g of glaze slurry and the glaze thickness parameters in the corresponding cells. The software will then automatically generate a correction amount conversion table for the total amount of inorganic pigment required for the production glaze. In the correction amount conversion table, technicians can quickly and intuitively find the corresponding corrective addition amount of inorganic pigment for the specific gravity and glaze amount parameters.

[0099] In Example 1, the specific gravity was 1.78, the glaze application amount was 90g, and the total pigment was 0.42g. The corresponding amount of added pigment for correction in the table is 0.449g. Please refer to [the table for details]. Figure 1 As shown;

[0100] In Example 2, the specific gravity was 1.85, the glaze application amount was 86g, and the total pigment was 0.72g. The corresponding amount of added pigment for correction in the table is 0.836g. Please refer to [the table for details]. Figure 2 As shown;

[0101] In Example 3, the specific gravity was 1.83, the glaze application amount was 87g, and the total pigment was 0.61g. The corresponding amount of added pigment for correction in the table is 0.693g. Please refer to [the table for details]. Figure 3 As shown;

[0102] Furthermore, when the amount of glaze applied in mass production remains constant but the specific gravity of the glaze needs to be adjusted to regulate the performance of the glaze slurry, increasing the specific gravity while keeping the amount of glaze constant will cause the glaze thickness to gradually decrease. In this case, the total amount of added pigment in the glaze slurry will also decrease, resulting in a gradually lighter color on the product. Conversely, decreasing the specific gravity while keeping the amount of glaze constant will cause the glaze thickness to gradually increase, resulting in a gradually darker color on the product. Please refer to [link / reference]. Figure 4 As shown, refer to the correction amount conversion table to find the correction amount value of the corresponding cell after adjusting the specific gravity while keeping the glaze amount unchanged. Based on the value, quickly adjust the total amount of added pigment to avoid and reduce the color difference caused by adjusting the specific gravity of the glaze.

[0103] Example 1: Due to performance requirements, the specific gravity of the glaze slurry needs to be increased from 1.78 to 1.82. Referring to the correction amount conversion table, find the cell corresponding to the two specific gravities for 90g of glaze. The amount of externally added correction pigment per 100g of glaze slurry increases from 0.449g to 0.459g. Please refer to [link / reference needed]. Figure 4 As shown;

[0104] If the production glaze has not yet been prepared, directly prepare the color glaze according to the correction amount of 0.459g. If the production glaze has been prepared, the specific gravity of the prepared glaze needs to be adjusted to 1.82, and 0.01g of the difference between the two pigments should be added to every 100g of glaze.

[0105] When the proportion of mass production remains unchanged and the amount of glaze needs to be adjusted to regulate product performance, the product will have color deviation due to the change in the amount of glaze. At this time, refer to the correction amount conversion table to find the correction amount value corresponding to the adjusted amount of glaze, and make quick adjustments according to the value to avoid and reduce the color difference caused by adjusting the amount of glaze.

[0106] Example 2: Due to product requirements, the glaze application amount needs to be increased by 2g, changing from 86g to 88g. Referring to the correction amount conversion table, find the intersecting cell corresponding to the 88g glaze amount for a specific gravity of 1.85. The additional pigment correction amount changes from 0.863g to 0.817g. If the glaze slurry has not yet been prepared, directly add pigment according to the correction amount of 0.817g. Please refer to [link / reference]. Figure 5As shown; if the production glaze has been adjusted to the original correction amount of 0.863g, a certain amount of white glaze of the same proportion can be added to the glaze to correct the color deviation caused by the increased glaze application amount through calculation.

[0107] Example 3: Due to product requirements, the glaze application amount needs to be reduced by 2g, changing from 87g to 85g. Referring to the correction amount conversion table, find the intersecting cell corresponding to the 85g glaze amount for a specific gravity of 1.83. The pigment correction amount changes from 0.693g to 0.709g. If the glaze slurry is not yet prepared, add pigment directly according to the correction amount of 0.709g. Please refer to [link to relevant documentation]. Figure 6 As shown. If the glaze slurry has already been prepared, pigments are added to the glaze slurry to correct the color deviation caused by reducing the amount of glaze applied;

[0108] Step (8) further includes: obtaining the corresponding pigment correction amount by reducing the amount of glaze: due to product requirements, the amount of glaze needs to be reduced by 2g, at which point the amount of glaze changes from 87g to 85g. Referring to the correction amount conversion table, find the intersecting cell corresponding to the 85g glaze amount with a specific gravity of 1.83, and the pigment correction amount changes from 0.693g to 0.709g. If the glaze slurry has not yet been prepared, add pigment directly according to the correction amount of 0.709g. If the glaze slurry has been prepared, add pigment to the glaze slurry to correct the color deviation caused by the reduction of the amount of glaze.

[0109] (9) Apply the prepared color glaze with corrected pigments to the production line, and obtain the plain color brick C after firing;

[0110] (10) Use a colorimeter to detect the change in the Lab value of the sample, calculate whether the ΔE between samples C and A is within the range, and determine whether the colors are consistent. If they are consistent or within the allowable range of color deviation, then produce according to this scheme. Further, test whether the color of the solid color brick C is consistent with that of the standard sample A. If they are consistent or within the allowable range of color deviation, then produce according to this scheme. If there is still a deviation, then make slight adjustments.

[0111] The resulting solid-color bricks with added inorganic color correction are close to the qualified standard sample; if there are slight differences, minor adjustments can be made.

[0112] The production of glaze uses a large amount, generally calculated in tons. The decimal in the correction table is taken to 3 decimal places. If there are more than 3 decimal places, the amount to be added is more precise. The setting in the Excel spreadsheet does not mean that this invention only takes 3 decimal places.

[0113] When the production ratio remains constant and the amount of glaze needs to be adjusted to regulate product performance, the product will have color deviation due to the change in the amount of glaze. At this time, refer to the correction amount conversion table to find the correction amount value corresponding to the adjusted amount of glaze, and make quick adjustments according to the value to avoid or reduce the color difference caused by adjusting the amount of glaze.

[0114] Regarding color difference representation:

[0115] Color difference is characterized by ΔE calculated using the CIE Lab system published by the International Commission on Illumination. The formula for ΔE color difference is:

[0116] ΔE=[(ΔL*) 2 +(Δa*) 2 +(Δb*) 2 ] 1 / 2

[0117] The correspondence between color difference values ​​and color perception levels is shown in the table below.

[0118] Correspondence between color difference value and color perception level

[0119]

[0120] The above description is only a preferred embodiment of the present invention. All equivalent changes and modifications made within the scope of the claims of the present invention should be covered by the claims of the present invention.

Claims

1. A method for corrective conversion between experimental and production processes of colored glaze solid-color bricks, characterized in that, Includes the following steps: (1) Based on the production of glaze trays with a specific gravity range of 1.75 to 1.86, a glaze application amount of 0.18 m², and a standard glazing area of ​​300 mm * 600 mm, the formula for calculating the glaze application amount per unit standard area of ​​brick blank is derived: ⑴ In the formula: h is the glaze thickness in mm; M is the glaze amount in g; d is the glaze density in g / cm³; s is the standard glaze area in mm². In the Excel spreadsheet, the amount of glaze applied is entered into a row, represented by row i; the density of the glaze paste is entered into a column, represented by column j, where i and j are both positive integers; then formula (1) is expressed as: (2) Obtain standard color sample A, which refers to the sample provided by the designer or end customer, for future use; (3) Obtain ceramic green bodies from the production line and clean the surface dust for later use; (4) Obtain the surface glaze for production, add inorganic pigments to the surface glaze according to the color of standard color sample A, and prepare the color glaze slurry for later use; (5) Place the experimental glaze preparation device at one end of the ceramic green body surface; pour the prepared color glaze slurry into the glaze preparation device; hold the edges of both ends of the glaze preparation device firmly with both hands, and pull the glaze preparation device to the other end of the green body parallel to the green body surface to apply the color glaze slurry to the green body surface; (6) After drying the glazed body, it was fired in the production kiln to obtain experimental sample B; (7) Compare the color of experimental sample B with that of standard color sample A. Use a colorimeter to detect the change in Lab value of the sample, calculate whether ΔE between the two is within the range, and confirm whether the color of experimental sample B is qualified. If experimental sample B is unqualified, repeat steps (3) to (6) until the experimental sample is qualified. (8) Based on the inorganic pigment scheme added to the qualified experimental sample B, and combined with the calculation formula for the amount of glaze applied in step (1), the correction formula for the amount of added inorganic pigment is obtained: ⑵ Where: m is the amount of inorganic pigment to be added, in g; h0 is the glaze thickness of qualified experimental sample B, in mm; h is the glaze thickness under actual production conditions obtained by formula (1), in mm; m0 is the amount of pigment added to qualified experimental sample B, in g; In the Excel spreadsheet, the amount of glaze applied is entered into a row, represented by row i; the proportion of glaze applied is entered into a column, represented by column j, where i and j are both positive integers; then equation (2) is expressed as: (9) Apply the prepared color glaze with the corrected amount of pigment to the production line, and after firing, obtain plain color brick C; (10) Use a colorimeter to detect the change in the Lab value of the sample, calculate whether the ΔE between C and A is within the range, and determine whether the colors are consistent. If they are consistent or within the allowable range of color deviation, then produce according to this scheme.

2. The method for correcting and converting the experimental and production processes of colored glaze solid-color bricks according to claim 1, characterized in that, Step (1) further includes: using Excel office software, taking glaze density d, glaze application amount M, and unit glaze application area s as input parameters, and automatically generating a production glaze amount thickness conversion table containing the corresponding glaze thickness h under different combinations of glaze application amount and glaze density according to formula (1).

3. The method for correcting and converting the experimental and production processes of colored glaze solid-color bricks according to claim 1, characterized in that, The step (8) further includes: using Excel office software, based on the glaze thickness h0 and pigment addition amount m0 ​​of the qualified experimental sample B, automatically generating a correction amount conversion table containing different glaze amounts, that is, the required inorganic pigment amount m corresponding to different h.

4. The method for correcting and converting the experimental and production processes of colored glaze solid-color bricks according to claim 3, characterized in that, When the amount of glaze needs to be adjusted during the production process, the amount of corrective inorganic pigment corresponding to the adjusted amount of glaze can be quickly found through the aforementioned correction amount conversion table, and the glaze slurry can be prepared accordingly.

5. The method for correcting and converting the experimental and production processes of colored glaze solid-color bricks according to claim 4, characterized in that, If the amount of glaze applied is increased and the glaze paste has already been prepared according to the original correction amount, the color deviation caused by the increased amount of glaze can be corrected by adding a set amount of white glaze paste with the same proportion as the production glaze paste to the prepared glaze paste.

6. The method for correcting and converting the experimental and production processes of colored glaze solid-color bricks according to claim 4, characterized in that, If the amount of glaze applied is reduced, and the glaze paste has already been prepared according to the original correction amount, the color deviation caused by the reduction in the amount of glaze applied can be corrected by adding a set amount of inorganic pigment to the prepared glaze paste.

7. The method for correcting and converting the experiment and production of colored glaze solid-color bricks according to claim 3, characterized in that, When the specific gravity of the glaze needs to be adjusted during the production process while the amount of glaze remains unchanged, the corresponding amount of corrective inorganic pigment m after the specific gravity adjustment can be quickly found through the aforementioned correction amount conversion table, and the glaze slurry can be prepared accordingly.

8. The method for correcting and converting the experimental and production processes of colored glaze solid-color bricks according to claim 7, characterized in that, If the specific gravity of the glaze is increased and the glaze has been prepared according to the original correction amount, then after adjusting the specific gravity of the glaze to the target value, add the corresponding inorganic pigment to the unit glaze according to the difference in the correction amount conversion table.

9. The method for correcting and converting the experimental and production processes of colored glaze solid-color bricks according to claim 1, characterized in that, Step (4) involves adding inorganic pigments to the glaze according to the color of standard color sample A to obtain the qualified experimental sample B. The formulation includes any of the following: (4.1) By mass ratio, the ratio of glaze paste to inorganic pigment is 150:0.63, which translates to 0.42g of inorganic pigment added to 100g of glaze paste with a specific gravity of 1.

78. (4.2) By mass ratio, the ratio of glaze slurry to inorganic pigment is 100:0.72, which translates to 0.72g of inorganic pigment added to 100g of glaze slurry with a specific gravity of 1.

85. (4.3) By mass ratio, the ratio of glaze paste to inorganic pigment is 200:1.22, which translates to 0.61g of inorganic pigment added to 100g of glaze paste with a specific gravity of 1.

83.

10. The method according to claim 1, characterized in that, The glaze preparation device used in step (5) is a glaze preparation device that can form a fixed glaze layer with a thickness of 0.3 mm on the surface of ceramic brick blanks.

11. The method according to claim 1, characterized in that, In step 6, the firing time is 90 minutes, the maximum firing temperature is 1180℃, and the holding time is 5 minutes.

12. The method according to claim 1, characterized in that, The color comparison described in step (7) uses a colorimeter to detect the Lab value of the sample and calculates the ΔE value. The formula for calculating ΔE is: ΔE=[(ΔL)²+(Δa)²+(Δb*)²]¹ / ².

13. The method according to claim 12, characterized in that, The correspondence between the ΔE value and the degree of color perception is as follows: 0.0 to 0.5 is a slight color difference, 0.5 to 1.51 is a small color difference, 1.5 to 3 is a relatively small color difference, and >3 is a relatively large color difference.

14. The method according to claim 3, characterized in that, In step 9, when preparing the colored glaze, the amount of pigment added is calculated in tons, and the correction amount conversion table is rounded to three decimal places.

15. The method according to claim 1, characterized in that, The surface glaze used in step (4) is a base surface glaze, and the inorganic pigment is one or more types.

16. The method according to claim 1, characterized in that, After the glazed body described in step 6 is dried, it is fired in the production kiln. The product specifications are 900×2600×9mm.

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