A method for preparing irregular cracked antique-style bricks

Abstract

This invention relates to a method for preparing irregularly cracked antique-style bricks, comprising applying a dry-granule glaze slurry to a surface glaze layer, wherein the melting temperature of the dry granules in the dry-granule glaze slurry is higher than the melting temperature of the surface glaze particles in the surface glaze slurry; and firing the brick blank after applying the surface glaze slurry and the dry-granule glaze slurry in a firing furnace. The method is characterized in that the dry-granule glaze slurry is composed of dry granules and a suspension in a weight ratio of 1.5-3:1; the particle size of the dry granules is 120-250 mesh, and the melting temperature is 1100-1200℃; the suspension comprises, by weight of raw materials, methyl ethylene glycol. 10-20 parts, water 15-35 parts, sodium carboxymethyl cellulose 45-75 parts, sodium pyrophosphate 1-5 parts; the melting temperature of the glaze particles is 1030-1105℃, and the firing temperature of the kiln is 1100-1200℃; during the firing process, the glaze particles gradually melt and flow because the firing temperature is higher than their melting temperature, while the dry particles are in an unmelted or semi-melted state and have poor fluidity because the firing temperature is lower than or equal to their melting temperature. The dry particles on the surface accumulate under the action of the glaze layer to form a network of crack lines.

Description

Technical Field

[0001] This invention relates to the field of ceramic tile technology, and in particular to a method for preparing an antique-style tile with irregular cracks. Background Technology

[0002] Antique-style tiles, with their unique patterns and luster, and resistance to fading, are favored by consumers and have gradually gained a foothold in my country's building ceramics industry.

[0003] Chinese patent documents disclose a technical solution with patent application number 201710839471.5, entitled "A Production Process for Antique-Style Ceramic Tiles." This technical solution involves spraying dry granules with a particle size of 110-210 mesh and a spherical shape onto the surface of the tile blank, thereby creating an uneven textured effect on the surface of the tile after firing. However, this technical solution still has some problems and shortcomings in production, as follows:

[0004] First, the method of spraying dry granules onto the surface of brick blanks is problematic. Since dry granules are microparticles with a particle size of 110-220 mesh, these fine dry granule dust particles can easily enter the human body through the respiratory tract, eyes, and skin, seriously affecting the physical and mental health of workers.

[0005] Secondly, the dry granules must be spherical. If they are flaky or other shapes, they will stick together and fail to create the desired sandstone or stone effect. Dry granules are usually made by grinding various minerals. The shape of the granules produced by grinding is highly random, and the yield of spherical granules cannot be guaranteed, which increases the manufacturing cost of dry granules.

[0006] Third, dry granule spraying involves spraying dry granules onto the surface of the tile blank through a spray booth. The solid dry granules can easily wear down the spray nozzles of the spray booth, resulting in greater equipment wear and higher production costs.

[0007] Therefore, given the aforementioned problems and shortcomings of the above technical solution, the applicant believes it is necessary to make technical improvements to the technical solution and provide a method for preparing irregular cracked antique bricks. Summary of the Invention

[0008] The purpose of this invention is to solve the above-mentioned problems and shortcomings, and to provide a method for preparing irregular cracked antique bricks. This method involves applying dry granule glaze slurry to the surface glaze slurry layer. The dry granule glaze slurry is a slurry-like material, which is dust-free and will not harm the health of workers. In the slurry-like dry granule glaze slurry, the solid dry granules are uniformly dispersed in the liquid phase. It can be uniformly applied to the surface glaze slurry layer without special shapes, and the preparation cost of dry granules is low. The slurry-like dry granule glaze slurry causes less wear on equipment, which helps to reduce production costs. During high-temperature firing, the surface glaze particles melt into a liquid and flow, while the dry granules hardly flow. The liquid surface glaze particles pull the dry granules to move, forming irregular crack patterns.

[0009] The technical solution of this invention is implemented as follows: a method for preparing an antique-style brick with irregular cracks, comprising applying a dry granule glaze slurry to a surface glaze slurry layer, wherein the melting temperature of the dry granules in the dry granule glaze slurry is higher than the melting temperature of the surface glaze particles in the surface glaze slurry; and placing the brick blank after applying the surface glaze slurry and the dry granule glaze slurry into a firing furnace for firing; characterized in that the dry granule glaze slurry is composed of dry granules and a suspension in a weight ratio of 1.5-3:1; the particle size of the dry granules is 120-250 mesh, and the melting temperature is 1100-1200℃; the suspension comprises, by weight of raw materials: 10- methyl ethylene glycol. 20 parts, water 15-35 parts, sodium carboxymethyl cellulose 45-75 parts, sodium pyrophosphate 1-5 parts; the melting temperature of the glaze particles is 1030-1105℃, and the firing temperature of the kiln is 1100-1200℃; during the firing process, the glaze particles gradually melt and flow because the firing temperature is higher than their melting temperature, while the dry particles are in a non-melting or semi-melting state and have poor fluidity because the firing temperature is lower than or equal to their melting temperature. The dry particles on the surface accumulate under the action of the glaze layer to form a network of crack lines, giving the surface of the fired brick an irregular crack pattern effect.

[0010] Preferably, the chemical composition of the dry granules by weight is as follows: Al2O3: 10-15.5 parts, SiO2: 50-60 parts, Fe2O3: 0.05-0.15 parts, Ti2O: 0.05-0.2 parts, CaO: 9-13 parts, K2O: 0.5-1.5 parts, MgO: 3-6 parts, Na2O: 1-3 parts, BaO: 4-8 parts, ZnO: 6-10 parts.

[0011] Preferably, the chemical composition of the surface glaze particles by weight is as follows: Al2O3: 10-15.5 parts, SiO2: 40-55 parts, Fe2O3: 0.1-0.2 parts, Ti2O: 0.1-0.3 parts, CaO: 5-10 parts, K2O: 5.5-10 parts, MgO: 3-9 parts, Na2O: 4-8 parts, BaO: 0.3-0.5 parts, ZnO: 2-4.5 parts, SrO: 2-6 parts.

[0012] The beneficial effects of this invention are as follows: (1) The dry granule glaze is a slurry material, and the dry granules are dispersed in the slurry material, avoiding the dry granules from floating in the air and generating no dust, thus avoiding harm to the health of the workers. (2) The shape of the dry granules does not affect the performance of the dry granule glaze because they are dispersed in the slurry material. In the preparation process of the dry granules, the shape of the particles does not need to be considered, as long as the particle size requirement is met, it is qualified. Thus, the preparation of dry granules can be carried out using mature equipment such as ball mills and rod mills, and the preparation cost is low. (3) The dry granule glaze is fluid and has good fluidity. In the process of applying the dry granule glaze, the dry granule glaze is not easy to clog the equipment, and the thickness, texture, and pattern of the dry granule glaze are easier to control. (4) During the firing process, the firing temperature is greater than the melting temperature of the glaze particles, causing the glaze particles to gradually melt and flow; the firing temperature is less than or equal to the melting temperature of the dry particles, causing the dry particles to be in a non-melting or semi-melting state with poor fluidity, so that the dry particles on the surface accumulate under the action of the glaze layer to form a network of crack lines, giving the surface of the fired brick an irregular crack pattern effect. Attached Figure Description

[0013] Figure 1 This is a product image of the antique-style brick of the present invention. Detailed Implementation

[0014] This invention provides a method for preparing antique-style bricks with irregular cracks, such as... Figure 1 As shown, it includes the following steps:

[0015] Step 1: Prepare the raw blank.

[0016] Step Two: Applying the base glaze. After spraying water onto the dried unglazed brick, apply the base glaze. The purpose of the base glaze is to cover imperfections on the unglazed brick and to adjust its shape. The preparation method of the base glaze in this invention is as follows:

[0017] First, the raw materials are prepared according to the specified proportions. The raw materials for the base glaze slurry, by weight, include: 42-53 parts potassium feldspar, 5-8 parts sodium feldspar, 8-16 parts calcined alumina, 12-22 parts calcined kaolin, 5-13 parts quartz, 3-8 parts dolomite, 0.5-1.5 parts zinc oxide, and 8-12 parts zirconium silicate. A preferred formulation is: 45-48 parts potassium feldspar, 5-6 parts sodium feldspar, 10-12 parts calcined alumina, 15-20 parts calcined kaolin, 8-10 parts quartz, 4-6 parts dolomite, 0.8-1.0 parts zinc oxide, and 9-10 parts zirconium silicate.

[0018] Then, the prepared raw material mixture and water are put into a ball mill for grinding. In order to adjust the suspension and fluidity of the glaze slurry, sodium carboxymethyl cellulose and Sichuan tripolymer are also added. The preferred amount of sodium carboxymethyl cellulose is 0.25% (by weight) and the preferred amount of Sichuan tripolymer is 0.3% (by weight). These materials are ground together in the ball mill to form a glaze slurry with a 250-mesh sieve residue of 0.5-0.7%.

[0019] Step 3: Apply the top glaze paste onto the base glaze layer. The preparation method of the top glaze paste is as follows:

[0020] First, the raw materials are prepared according to the specified proportions. The raw materials for the glaze slurry, by weight, include: 37-45 parts potassium feldspar, 10-16 parts dolomite, 0.5-1 part barium carbonate, 6-12 parts ceramic frit, 5-10 parts washed clay, 2.5-5 parts calcined talc, 2-5 parts zinc oxide, and 5-8 parts quartz. A preferred formulation is: 40-43 parts potassium feldspar, 12-14 parts dolomite, 0.8-0.9 parts barium carbonate, 8-10 parts ceramic frit, 7-9 parts washed clay, 3.5-4.5 parts calcined talc, 3-3.5 parts zinc oxide, and 6-7 parts quartz.

[0021] The chemical composition of the ceramic frit is as follows: Al2O3: 15-20 parts, SiO2: 30-45 parts, CaO: 10-20 parts, K2O: 8-15 parts, MgO: 6-15 parts, Na2O: 4-6 parts, ZnO: 3-5 parts, SrO: 0.01-0.1 parts.

[0022] Then, the prepared raw material mixture, along with water, sodium carboxymethyl cellulose, and Sichuan triterpenoids, is placed in a ball mill and ground to a fineness of 0.3-0.5% residue on a 250-mesh sieve. The amount of sodium carboxymethyl cellulose used is 0.15wt%-0.25wt% (by weight), and the amount of Sichuan triterpenoids used is 0.25wt%-0.4wt% (by weight). A preferred formulation is: sodium carboxymethyl cellulose used is 0.2wt% (by weight), and Sichuan triterpenoids used is 0.3wt% (by weight).

[0023] The chemical components in the glaze paste are as follows by weight: Al2O3: 10-15.5 parts, SiO2: 40-55 parts, Fe2O3: 0.1-0.2 parts, Ti2O: 0.1-0.3 parts, CaO: 5-10 parts, K2O: 5.5-10 parts, MgO: 3-9 parts, Na2O: 4-8 parts, BaO: 0.3-0.5 parts, ZnO: 2-4.5 parts, SrO: 2-6 parts. The preferred composition is: Al2O3: 11-12 parts, SiO2: 42-45 parts, Fe2O3: 0-0.15 parts, Ti2O: 0-0.15 parts, CaO: 5-10 parts, K2O: 7.5-8.5 parts, MgO: 5.5-7.2 parts, Na2O: 5-6 parts, BaO: 0.4-0.5 parts, ZnO: 2.8-3.5 parts, SrO: 3-4 parts.

[0024] By adjusting the content of refractory oxides (Al2O3 and SiO2) and fusible oxides (alkali metal oxides) in the glaze slurry, the melting temperature of the glaze layer is kept within the range of 1030-1105℃. This not only gives the surface of the antique bricks good stain resistance and wear resistance, but also allows the glaze layer to have good fluidity during firing, thus enabling the dry particles to move and form accumulated lines.

[0025] Step 4: Inkjet print the pattern onto the glaze layer. Combining inkjet printing with pattern design can enhance the three-dimensional effect of antique-style tiles.

[0026] Step 5: Apply dry granule glaze slurry. The preparation method of the dry granule glaze slurry is as follows:

[0027] First, the raw materials are prepared according to the specified proportions. The raw materials for the dry granule glaze, by weight, include: 5-12 parts potassium-sodium feldspar, 40-50 parts potassium feldspar, 3-8 parts calcined alumina, 6-10 parts zinc oxide, 1-5 parts calcined talc, 12-20 parts wollastonite, and 4-8 parts barium carbonate. A preferred formulation is: 8-10 parts potassium-sodium feldspar, 45-48 parts potassium feldspar, 6-7 parts calcined alumina, 7-9 parts zinc oxide, 2-3 parts calcined talc, 14-16 parts wollastonite, and 6-7 parts barium carbonate.

[0028] Then, after mixing the aforementioned raw materials, they are placed in a frit furnace and calcined at high temperature to produce frit.

[0029] Next, the aforementioned frit and suspending agent are placed together in a ball mill for grinding to produce a dry granule glaze slurry. The particle size of the dry granule glaze slurry is 120-250 mesh. The ratio of suspending agent to dry granules is 1.5-3:1, with a preferred ratio of 2:1.

[0030] The suspending agent has the following composition: 10-20 parts methyl ethylene glycol, 15-35 parts water, 45-75 parts sodium carboxymethyl cellulose, and 1-5 parts sodium pyrophosphate. A preferred composition is: 15-18 parts methyl ethylene glycol, 20-30 parts water, 55-70 parts sodium carboxymethyl cellulose, and 3-4 parts sodium pyrophosphate.

[0031] The chemical composition range of dry granules is as follows: Al2O3: 10-15.5 parts, SiO2: 50-60 parts, Fe2O3: 0.05-0.15 parts, Ti2O: 0.05-0.2 parts, CaO: 9-13 parts, K2O: 0.5-1.5 parts, MgO: 3-6 parts, Na2O: 1-3 parts, BaO: 4-8 parts, ZnO: 6-10 parts. The preferred composition is: Al2O3: 12-15 parts, SiO2: 52-56 parts, Fe2O3: 0.1-0.15 parts, Ti2O: 0.15-0.2 parts, CaO: 10-11 parts, K2O: 0.8-1.0 parts, MgO: 4-5 parts, Na2O: 1-3 parts, BaO: 4-6 parts, ZnO: 7-8 parts.

[0032] The dry granule glaze is evenly poured onto the surface of the ceramic tile blank using a bell-shaped glazing device.

[0033] The dry granule glaze contains a relatively high amount of refractory components (Al2O3 and SiO2) and a relatively low amount of easily fusible alkali metal oxides. Therefore, the dry granules have a high melting temperature of 1100-1200℃. In this way, during the ceramic tile firing process, the dry granules can maintain their granular state and are not easily melted.

[0034] Step 5: Place the unglazed antique-style tile blank with the applied dry granule glaze into the firing kiln for firing. The firing temperature is controlled at 1150-1200℃, and the firing time is 40-50 minutes. At this firing temperature, because the melting temperature of the glaze particles is 1030-1105℃, the glaze layer melts into a liquid state. Furthermore, the firing temperature is about 100℃ higher than the melting temperature of the glaze particles, giving the glaze layer a certain fluidity, causing it to flow outwards. Meanwhile, the melting temperature of the dry granules is 1100-1200℃, keeping the dry granules in a non-melting or semi-melting state and almost non-flowing. This allows some dry granules to embed into the molten glaze layer, while others flow with the glaze layer, accumulating to form dry granule lines of varying thickness and length. These lines form a network pattern of varying sizes and densities on the surface of the unglazed tile blank, creating a three-dimensional crackled pattern effect.

[0035] Step Six: Semi-polish the fired antique-style bricks. Because the dry granules have a high melting temperature, they hardly melt during firing, resulting in relatively rough lines. After semi-polishing, compared to areas without dry granule accumulation, the lines formed by the dry granules have a brighter gloss, while the areas without dry granule accumulation have a duller gloss. This combination of gloss and matte finish enhances the layering of the brick surface. Furthermore, the varying thickness, size, length, and density of the mesh-like lines give the antique-style bricks a strong three-dimensional feel.

[0036] To further illustrate the present invention, specific embodiments are provided below.

[0037] Example 1: A method for preparing an antique-style brick with irregular cracks, comprising the following steps:

[0038] S1: Prepare the unfinished antique-style brick blank;

[0039] S2: Apply base glaze;

[0040] S3: Apply surface glaze;

[0041] S4: Use an inkjet printer to print the pattern;

[0042] S5: Apply dry granule glaze;

[0043] S6: High-temperature firing, with the firing temperature controlled at 1200℃ and the time being 50 minutes;

[0044] S7: Semi-polishing.

[0045] The raw materials used in the preparation of the base glaze in this embodiment include, by weight, 45 parts potassium feldspar, 6 parts sodium feldspar, 10 parts calcined alumina, 0 parts calcined kaolin, 10 parts quartz, 4 parts dolomite, 1.0 part zinc oxide, and 9 parts zirconium silicate.

[0046] Then, the prepared raw material mixture, along with water, sodium carboxymethyl cellulose, and Chuandong terpene, is placed in a ball mill for grinding. The aforementioned materials are ground into a glaze slurry with a residue of 0.5-0.7% on a 250-mesh sieve. The amount of sodium carboxymethyl cellulose used is 0.25% (by weight), and the amount of Chuandong terpene is 0.3% (by weight).

[0047] The raw materials used in the preparation of the glaze in this embodiment include, by weight, 42 parts potassium feldspar, 15 parts dolomite, 0.6 parts barium carbonate, 7 parts ceramic frit, 8 parts washed clay, 4 parts calcined talc, 3 parts zinc oxide, and 5 parts quartz.

[0048] The chemical composition of the ceramic frit is as follows: Al2O3: 15 parts, SiO2: 30 parts, CaO: 1 part, K2O: 12 parts, MgO: 8 parts, Na2O: 5 parts, ZnO: 3 parts, SrO: 0.01-0.1 parts.

[0049] The aforementioned raw materials, along with water, sodium carboxymethyl cellulose, and Chuandong terpene, were placed in a ball mill and ground. The resulting glaze slurry had a residue of 0.3-0.5% on a 250-mesh sieve. The amount of sodium carboxymethyl cellulose used was 0.2% (by weight), and the amount of Chuandong terpene was 0.3% (by weight).

[0050] The chemical components in the glaze paste are as follows by weight: Al2O3: 12 parts, SiO2: 50 parts, Fe2O3: 0.2 parts, Ti2O: 0.3 parts, CaO: 9 parts, K2O: 8 parts, MgO: 8 parts, Na2O: 6 parts, BaO: 0.5 parts, ZnO: 6 parts, SrO: 2 parts.

[0051] The raw materials used in the preparation of the dry granules in this embodiment, by weight, include: preferably 8 parts of potassium-sodium feldspar, 45 parts of potassium feldspar, 5 parts of calcined alumina, 7 parts of zinc oxide, 2 parts of calcined talc, 14 parts of wollastonite, and 6 parts of barium carbonate. Then, the aforementioned raw materials are mixed well, placed in a frit furnace for high-temperature calcination, and water-quenched to produce frit.

[0052] Then, the aforementioned frit and suspending agent are placed together in a ball mill for grinding to produce a dry granule glaze slurry. The dry granule glaze slurry has a particle size of 200-220 mesh, and the ratio of suspending agent to dry granules is 2:1. The suspending agent is formulated as follows: 17 parts methyl ethylene glycol, 15 parts water, 65 parts sodium carboxymethyl cellulose, and 3 parts sodium pyrophosphate.

[0053] The chemical composition of the obtained dry granules is as follows: Al2O3: 12 parts, SiO2: 55.5 parts, Fe2O3: 0.12 parts, Ti2O: 0.15 parts, CaO: 11 parts, K2O: 1.2 parts, MgO: 4.5 parts, Na2O: 2.5 parts, BaO: 6 parts, ZnO: 7 parts.

[0054] like Figure 1 As shown in this embodiment, the antique-style bricks made by firing and semi-polishing have a combination of glossy and matte surfaces. Their mesh lines vary in thickness, size, length, density, and sparseness, creating a strong sense of three-dimensional layering.

Claims

1. A method for preparing an antique brick with irregular cracks, comprising applying a dry granular glaze on a surface glaze layer, wherein the dry granular glaze has a melting temperature higher than that of the surface glaze particles in the surface glaze; and firing the brick in a firing furnace after applying the surface glaze and the dry granular glaze; characterized in that: the dry granular glaze is composed of dry granules and a suspension in a weight ratio of 1.5-3:1; the dry granules have a particle size of 120-250 mesh and a melting temperature of 1100-1200℃; the suspension comprises, in parts by weight of raw materials, 10-20 parts of methyl glycol, 15-35 parts of water, 45-75 parts of sodium carboxymethyl cellulose, and 1-5 parts of sodium pyrophosphate; the surface glaze particles have a melting temperature of 1030-1105℃, and the firing temperature of the firing furnace is 1100-1200℃; during the firing process, the surface glaze particles gradually melt and flow due to the firing temperature being higher than their melting temperature, while the dry granules are in a non-melting or semi-melting state and have poor flowability due to the firing temperature being less than or equal to their melting temperature, and the dry granules on the surface are accumulated to form a network of crack lines under the driving of the surface glaze layer, so that the fired brick has an irregular crack pattern effect. The dry granules have a chemical composition of, in parts by weight: Al2O3: 10-15.5, SiO2: 50-60, Fe2O3: 0.05-0.15, Ti2O: 0.05-0.2, CaO: 9-13, K2O: 0.5-1.5, MgO: 3-6, Na2O: 1-3, BaO: 4-8, and ZnO: 6-10. The surface glaze particles have a chemical composition of, in parts by weight: Al2O3: 10-15.5, SiO2: 40-55, Fe2O3: 0.1-0.2, Ti2O: 0.1-0.3, CaO: 5-10, K2O: 5.5-10, MgO: 3-9, Na2O: 4-8, BaO: 0.3-0.5, ZnO: 2-4.5, and SrO: 2-6. ​ ​ 2. The method of claim 1, wherein the irregularly cracked antique brick is prepared by the steps of: ​ ​ 3. The method of claim 1, wherein the irregularly cracked antique brick is prepared by the steps of: ​ ​

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