A protective glaze, a stone-like ceramic tile and its preparation method

Abstract

This invention discloses a protective glaze, an imitation stone ceramic tile, and a method for preparing the same, relating to the field of ceramic tile preparation. The protective glaze, by weight, comprises the following components: 8-10 parts potassium feldspar, 10-15 parts first frit, 15-22 parts calcined kaolin, 12-17 parts nepheline, 6-9 parts calcined zinc oxide, 14-17 parts quartz, 12-20 parts corundum, 3-5 parts calcined talc, and 14-18 parts zirconium silicate. When combined with a deep-inking process, the protective glaze can produce a glaze surface with deep concave textures, enhancing the stone-like effect.

Description

Technical Field

[0001] This invention relates to the field of ceramic tile preparation, and in particular to a protective glaze, a stone-like ceramic tile, and a method for preparing the same. Background Technology

[0002] Today's consumers, seeking a more natural visual effect, are increasingly choosing ceramic tiles with a stone-like finish. For stone-like ceramic tiles to achieve a truly realistic visual effect, they need to closely resemble stone not only in gloss, color, and texture, but also in feel. The simulation of the tactile feel involves the textured surface of the ceramic tile; the varying heights of the texture affect light reflection, thus influencing the visual effect. Currently, ceramic tiles with textured surfaces have a relatively shallow depth of texture, making it difficult to accurately achieve the effect of real stone.

[0003] It is evident that existing technologies still need improvement and enhancement. Summary of the Invention

[0004] In view of the shortcomings of the prior art, the purpose of the present invention is to provide a protective glaze, a stone-like ceramic tile and a method for preparing the same, in order to solve the technical problem that the surface texture of ceramic tiles with raised or recessed textures is relatively shallow in the prior art.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A protective glaze, by weight, comprises the following components in its preparation: 8-10 parts potassium feldspar, 10-15 parts first frit, 15-22 parts calcined kaolin, 12-17 parts nepheline, 6-9 parts calcined zinc oxide, 14-17 parts quartz, 12-20 parts corundum, 3-5 parts calcined talc, and 14-18 parts zirconium silicate.

[0007] The protective glaze, wherein, by weight percentage, the chemical composition of the first frit comprises: SiO2 49.7%–52.4%, Al2O3 14%–16.7%, MgO 2.2%–3.7%, CaO 3.5%–5.3%, Na2O 1%–2.5%, K2O 1.5%–2.8%, BaO 10.5%–12.7%, ZnO 4.2%–5.8%, with the balance being loss on ignition.

[0008] A stone-like ceramic tile includes a tile body layer, a base glaze layer, and a textured layer arranged sequentially, wherein the textured layer is made of deep ink and the protective glaze described above.

[0009] The aforementioned imitation stone ceramic tile, wherein, by weight, the deep ink comprises the following components: 40-45 parts of second frit, 50-55 parts of organic solvent, 5-8 parts of dispersant, 0.8-1 part of defoamer, and 3-4 parts of anti-settling agent.

[0010] The aforementioned stone-like ceramic brick, wherein, by weight percentage, the second frit comprises the following components: SiO2 50%–55%, Al2O3 10%–12%, MgO 0.3%–0.8%, CaO 6.5%–8.2%, Na2O 1%–2.5%, K2O 4.5%–6.8%, BaO 12%–15%, ZnO 2.5%–4%, B2O3 0.4%–1.7%, with the balance being loss on ignition.

[0011] The aforementioned imitation stone ceramic tile, wherein the base glaze layer is obtained by firing a base glaze, and the raw materials for preparing the base glaze, by weight, include the following components: 12-18 parts potassium feldspar, 10-20 parts sodium feldspar, 7-12 parts calcined kaolin, 5-10 parts kaolin, 8-13 parts quartz, 10-12 parts nepheline, 14-18 parts calcined alumina, 2-5 parts calcined zinc oxide, and 12-16 parts zirconium silicate.

[0012] A method for preparing ceramic tiles, used to prepare the stone-like ceramic tiles as described above, includes the following steps:

[0013] Apply a base glaze to the brick blank to create a base glaze layer;

[0014] Print deep ink onto the base glaze layer, then apply a protective glaze to create a textured layer.

[0015] The stone-like ceramic bricks are then fired, polished, and produced.

[0016] The method for preparing ceramic bricks, wherein the firing temperature of the imitation stone ceramic bricks is 1180~1210℃.

[0017] In the method for preparing ceramic tiles, the specific gravity of the protective glaze slurry is 1.88–1.90 mg / L.

[0018] In the method for preparing ceramic tiles, the specific gravity of the base glaze slurry is 1.88–1.90 mg / L.

[0019] Beneficial effects:

[0020] The first aspect of the present invention provides a protective glaze, which has a low melting viscosity at high temperatures and a high melting viscosity at low temperatures. When used in conjunction with a deep ink, it can produce a deep, textured surface, and the glaze layer has good wear resistance.

[0021] The second aspect of the present invention provides a stone-like ceramic tile, wherein the textured layer of the stone-like ceramic tile is obtained by firing the above-mentioned protective glaze and deep ink, and its texture has a large depth and obvious undulation in the touch, so that the stone-like ceramic tile has a good stone-like effect.

[0022] The third invention provides a method for preparing ceramic tiles. The method is used to prepare the stone-like ceramic tiles as described above. The method adopts a one-time firing process, which is mature and has a low defect rate. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the layered structure of the stone-like ceramic brick provided by the present invention.

[0024] Explanation of main component symbols: 1- Textured layer, 2- Base glaze layer, 3- Brick body layer. Detailed Implementation

[0025] This invention provides a protective glaze, a stone-like ceramic tile, and a method for preparing the same. To make the objectives, technical solutions, and effects of this invention clearer and more explicit, the invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only for explaining the invention and are not intended to limit the invention.

[0026] In the description of this invention, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature.

[0027] This invention provides a protective glaze, which, by weight, comprises the following components: 8-10 parts potassium feldspar, 10-15 parts first frit, 15-22 parts calcined kaolin, 12-17 parts nepheline, 6-9 parts calcined zinc oxide, 14-17 parts quartz, 12-20 parts corundum, 3-5 parts calcined talc, and 14-18 parts zirconium silicate. The first frit is used to adjust the high-temperature melt viscosity of the protective glaze, ensuring its fluidity is not too good. Calcined kaolin increases the hardness and wear resistance of the glaze surface and also enhances its adhesion. Nepheline adjusts the coefficient of thermal expansion of the glaze, reducing the formation of defects after firing. Calcined zinc oxide has a strong fluxing effect in the glaze, reducing its coefficient of thermal expansion and improving the product's thermal stability. Quartz reduces the glaze's fluidity, contributing to increased texture depth. Corundum increases the hardness and wear resistance of the glaze layer. Calcined talc acts as a solvent, effectively lowering the firing temperature. Zirconium silicate is used for opacification and whitening. The protective glaze, through the combination of the above components, exhibits low viscosity and high fluidity at high temperatures, promoting the interaction of the components and the formation of crystals; at low temperatures, it exhibits high viscosity and low fluidity, resulting in a high depth of textured surface.

[0028] Preferably, the chemical composition of the first frit, by weight percentage, includes: SiO2 49.7%–52.4%, Al2O3 14%–16.7%, MgO 2.2%–3.7%, CaO 3.5%–5.3%, Na2O 1%–2.5%, K2O 1.5%–2.8%, BaO 10.5%–12.7%, ZnO 4.2%–5.8%, with the balance being loss on ignition. Among the above components, the alkaline earth metal oxides CaO, MgO, and BaO can reduce the viscosity of the glaze at high temperatures, while increasing it at low temperatures. The high content of alkaline earth metal oxides in the first frit promotes rapid melting of other raw materials at high temperatures, but the viscosity gradually increases and fluidity decreases as the temperature gradually decreases.

[0029] In the existing technology, when the protective glaze is used in combination with the deep ink, during the high-temperature firing process, after the hydrophobic components in the deep ink have completely evaporated, a small portion of the molten protective glaze will flow to the top of the deep ink and combine with the components in the deep ink, which will result in a shallower depression area and shallower texture at the deep ink.

[0030] The protective glaze of this invention melts the components at high temperature. As the kiln temperature decreases, the viscosity of the protective glaze increases rapidly and the fluidity decreases sharply. Only a very small amount of protective glaze covers the non-volatile components of the deep ink, thus ensuring a large depth of the texture.

[0031] Please see Figure 1A stone-like ceramic tile includes a brick body layer 3, a base glaze layer 2, and a textured layer 1 arranged sequentially, wherein the textured layer is made of deep ink and the protective glaze described above.

[0032] Preferably, the ink comprises the following components by weight: 40-45 parts of second frit, 50-55 parts of organic solvent, 5-8 parts of dispersant, 0.8-1 part of defoamer, and 3-4 parts of anti-settling agent.

[0033] Preferably, the second frit, by weight percentage, comprises the following components: SiO2 50%–55%, Al2O3 10%–12%, MgO 0.3%–0.8%, CaO 6.5%–8.2%, Na2O 1%–2.5%, K2O 4.5%–6.8%, BaO 12%–15%, ZnO 2.5%–4%, B2O3 0.4%–1.7%, with the balance being loss on ignition.

[0034] Preferably, the base glaze layer is obtained by firing a base glaze. By weight, the raw materials for preparing the base glaze include the following components: 12-18 parts potassium feldspar, 10-20 parts sodium feldspar, 7-12 parts calcined kaolin, 5-10 parts kaolin, 8-13 parts quartz, 10-12 parts nepheline, 14-18 parts calcined alumina, 2-5 parts calcined zinc oxide, and 12-16 parts zirconium silicate. The calcined kaolin, calcined alumina, and calcined zinc oxide, after calcination, produce less gas during firing, which can effectively reduce defects in the glaze layer.

[0035] A method for preparing ceramic tiles, used to prepare the stone-like ceramic tiles as described above, includes the following steps:

[0036] Apply a base glaze to the brick blank to create a base glaze layer;

[0037] Print deep ink onto the base glaze layer, then apply a protective glaze to create a textured layer.

[0038] The stone-like ceramic bricks are then fired, polished, and produced.

[0039] Preferably, the firing temperature of the stone-like ceramic brick is 1180-1210℃.

[0040] Preferably, the specific gravity of the protective glaze slurry is 1.88 to 1.90 mg / L.

[0041] Preferably, the specific gravity of the base glaze slurry is 1.88 to 1.90 mg / L.

[0042] The present invention will be further illustrated by the following examples and comparative examples.

[0043] Example 1

[0044] A stone-like ceramic tile is prepared by the following steps:

[0045] S001. Apply a base glaze to the brick blank layer to obtain a base glaze layer;

[0046] S002. Print deep ink on the base glaze layer with a gray level of 70, and then apply a protective glaze to create a textured layer.

[0047] S003. Firing, the firing temperature is 1180~1210℃, and after firing, polishing is performed to obtain the stone-like ceramic tile;

[0048] In S001, by weight, the raw materials for preparing the base glaze include the following components: 15 parts potassium feldspar, 14 parts sodium feldspar, 9 parts calcined kaolin, 7 parts kaolin, 11 parts quartz, 10 parts nepheline, 16 parts calcined alumina, 4 parts calcined zinc oxide, and 14 parts zirconium silicate.

[0049] The specific gravity of the base glaze slurry is 1.88–1.90 mg / L;

[0050] In S002, by weight, the raw materials for preparing the protective glaze include the following components: 9 parts potassium feldspar, 12 parts first frit, 17 parts calcined kaolin, 15 parts nepheline, 8 parts calcined zinc oxide, 15 parts quartz, 18 parts corundum, 4 parts calcined talc, and 16 parts zirconium silicate.

[0051] The chemical composition of the first fused block, by weight percentage, includes: SiO2 51.5%, Al2O3 15.3%, MgO 3.2%, CaO 4.6%, Na2O 2.4%, K2O 2.5%, BaO 12.3%, ZnO 5.3%, with the balance being loss on ignition.

[0052] The specific gravity of the protective glaze slurry is 1.88–1.90 mg / L;

[0053] By weight, the deep ink comprises the following components: 44 parts of second frit, 51 parts of organic solvent, 7 parts of dispersant, 0.8 parts of defoamer, and 3 parts of anti-settling agent;

[0054] The second fused block comprises, by weight percentage: 52.2% SiO2, 11.3% Al2O3, 0.5% MgO, 6.8% CaO, 2.1% Na2O, 6.2% K2O, 14.2% BaO, 3.7% ZnO, 1.1% B2O3, with the balance being loss on ignition.

[0055] Example 2

[0056] The preparation method of a stone-like ceramic tile differs from that of Example 1 in that:

[0057] The base glaze and the protective glaze have different formulations;

[0058] In this embodiment, the raw materials for preparing the base glaze, by weight, include the following components: 18 parts potassium feldspar, 11 parts sodium feldspar, 8 parts calcined kaolin, 8 parts kaolin, 12 parts quartz, 10 parts nepheline, 15 parts calcined alumina, 5 parts calcined zinc oxide, and 16 parts zirconium silicate.

[0059] The raw materials for preparing the protective glaze, by weight, include the following components: 10 parts potassium feldspar, 11 parts first frit, 21 parts calcined kaolin, 15 parts nepheline, 8 parts calcined zinc oxide, 14 parts quartz, 13 parts corundum, 5 parts calcined talc, and 15 parts zirconium silicate.

[0060] Example 3

[0061] The preparation method of a stone-like ceramic tile differs from that of Example 1 in that:

[0062] The base glaze and the protective glaze have different formulations;

[0063] In this embodiment, the raw materials for preparing the base glaze, by weight, include the following components: 18 parts potassium feldspar, 15 parts sodium feldspar, 12 parts calcined kaolin, 5 parts kaolin, 13 parts quartz, 10 parts nepheline, 14 parts calcined alumina, 2 parts calcined zinc oxide, and 16 parts zirconium silicate.

[0064] The raw materials for preparing the protective glaze, by weight, include the following components: 9 parts potassium feldspar, 15 parts first frit, 16 parts calcined kaolin, 14 parts nepheline, 8 parts calcined zinc oxide, 14 parts quartz, 16 parts corundum, 5 parts calcined talc, and 15 parts zirconium silicate.

[0065] Comparative Example 1

[0066] The preparation method of a stone-like ceramic tile differs from that of Example 1 in that:

[0067] The protective glazes have different formulas;

[0068] In this comparative example, the raw materials for preparing the protective glaze, by weight, include the following components: 13 parts potassium feldspar, 8 parts first frit, 17 parts calcined kaolin, 15 parts nepheline, 8 parts calcined zinc oxide, 15 parts quartz, 18 parts corundum, 4 parts calcined talc, and 16 parts zirconium silicate.

[0069] Comparative Example 2

[0070] The preparation method of a stone-like ceramic tile differs from that of Example 1 in that:

[0071] The protective glazes have different formulas;

[0072] In this comparative example, the raw materials for preparing the protective glaze, by weight, include the following components: 8 parts potassium feldspar, 17 parts first frit, 16 parts calcined kaolin, 14 parts nepheline, 8 parts calcined zinc oxide, 15 parts quartz, 18 parts corundum, 4 parts calcined talc, and 16 parts zirconium silicate.

[0073] Comparative Example 3

[0074] The preparation method of a stone-like ceramic tile differs from that of Example 1 in that:

[0075] The protective glazes have different formulas;

[0076] In this comparative example, the third melting block is used to replace the first melting block;

[0077] The chemical composition of the third fused block, by weight percentage, includes: SiO2 54.3%, Al2O3 17.2%, MgO 2.4%, CaO 3.1%, Na2O 3.8%, K2O 3.2%, BaO 8.2%, ZnO 6.2%, with the balance being loss on ignition.

[0078] Comparative Example 4

[0079] The preparation method of a stone-like ceramic tile differs from that of Example 1 in that:

[0080] The protective glazes have different formulas;

[0081] In this comparative example, the fourth melting block is used to replace the first melting block;

[0082] The chemical composition of the fourth fused block, by weight percentage, includes: SiO2 51.1%, Al2O3 15.2%, MgO 6.5%, CaO 5.7%, Na2O 1.2%, K2O 2.3%, BaO 13.2%, ZnO 2.4%, with the balance being loss on ignition.

[0083] The depth of the glaze grooves and the wear resistance of the stone-like ceramic tiles in Examples 1-3 and Comparative Examples 1-4 were measured, and the corresponding test results are as follows:

[0084] concave depth abrasion resistance Example 1 0.25mm Level 4 Example 2 0.23mm Level 4 Example 3 0.25mm Level 4 Comparative Example 1 0.18mm Level 4 Comparative Example 2 0.22mm Level 3 Comparative Example 3 0.15mm Level 4 Comparative Example 4 0.23mm Level 3

[0085] The results above show that the depth of the concave texture on the glaze of the imitation stone ceramic tiles in Examples 1-3 is between 0.23 and 0.25 mm. They have good wear resistance and a noticeable undulating feel when touched, which can closely resemble the feel of real stone.

[0086] In Comparative Example 1, the amount of the first frit used was less than the protection scope of the present invention. According to its test results, the depth of the concave texture on the glaze surface was shallow, only 0.18 mm, which was much smaller than that in Examples 1-3. The reason is that the amount of the first frit used was too small, and the proportion of potassium feldspar would increase. The protective glaze has low viscosity and good fluidity in the molten state. After the solvent of the deep ink evaporates, it will cover more of the deep ink, resulting in a shallower concave texture.

[0087] In Comparative Example 2, the amount of the first frit used was higher than the protection scope of the present invention. According to the test results, although the depth of the grooves on the glaze was deeper, its wear resistance was insufficient. The reason is that excessive use of the first frit would enhance the high-temperature melting ability, resulting in a decrease in the amount of hard crystals formed, thereby reducing the wear resistance of the glaze.

[0088] In Comparative Example 3, a third frit was used instead of the first frit. The test results showed that the depth of the concave texture on the glaze was shallower. This is because the content of alkaline earth metal oxides in the second frit was lower, which would lead to a decrease in viscosity at low temperatures and an increase in fluidity, resulting in the same problem as in Comparative Example 1.

[0089] In Comparative Example 4, the fourth frit was used instead of the first frit. According to the test results, although the depth of the grooves on the glaze surface was deeper, its wear resistance was also insufficient. The reason is that the fourth frit has a higher content of alkaline earth metal oxides, resulting in an overall excessively high content of alkaline earth metal oxides and alkali metal oxides. This leads to an excessively strong high-temperature melting ability, which is not conducive to the formation of hard crystals, and therefore the wear resistance is not high.

[0090] It is understood that those skilled in the art can make equivalent substitutions or modifications to the technical solution and inventive concept of the present invention, and all such substitutions or modifications should fall within the protection scope of the appended claims.

Claims

1. A protective glaze, characterized in that, The raw materials for its preparation, by weight, include the following components: 8-10 parts potassium feldspar, 10-15 parts first frit, 15-22 parts calcined kaolin, 12-17 parts nepheline, 6-9 parts calcined zinc oxide, 14-17 parts quartz, 12-20 parts corundum, 3-5 parts calcined talc, and 14-18 parts zirconium silicate. The chemical composition of the first frit, by weight percentage, includes: 49.7%-52.4% SiO2, 14%-16.7% Al2O3, 2.2%-3.7% MgO, 3.5%-5.3% CaO, 1%-2.5% Na2O, 1.5%-2.8% K2O, 10.5%-12.7% BaO, and 4.2%-5.8% ZnO, with the balance being loss on ignition.

2. A stone-like ceramic tile, characterized in that, It includes a brick blank layer, a base glaze layer and a textured layer arranged in sequence, wherein the textured layer is made of deep ink and the protective glaze as described in claim 1.

3. The stone-like ceramic tile according to claim 2, characterized in that, The ink comprises, by weight, the following components: 40-45 parts of second frit, 50-55 parts of organic solvent, 5-8 parts of dispersant, 0.8-1 part of defoamer, and 3-4 parts of anti-settling agent.

4. The stone-like ceramic tile according to claim 3, characterized in that, The second frit, by weight percentage, comprises the following components: SiO2 50%–55%, Al2O3 10%–12%, MgO 0.3%–0.8%, CaO 6.5%–8.2%, Na2O 1%–2.5%, K2O 4.5%–6.8%, BaO 12%–15%, ZnO 2.5%–4%, B2O3 0.4%–1.7%, with the balance being loss on ignition.

5. The stone-like ceramic tile according to claim 2, characterized in that, The base glaze layer is obtained by firing the base glaze. By weight, the raw materials for preparing the base glaze include the following components: 12-18 parts potassium feldspar, 10-20 parts sodium feldspar, 7-12 parts calcined kaolin, 5-10 parts kaolin, 8-13 parts quartz, 10-12 parts nepheline, 14-18 parts calcined alumina, 2-5 parts calcined zinc oxide, and 12-16 parts zirconium silicate.

6. A method for preparing ceramic bricks, characterized in that, The method for preparing the stone-like ceramic brick according to any one of claims 2-5 comprises the following steps: Apply a base glaze to the brick blank to create a base glaze layer; Print deep ink onto the base glaze layer, then apply a protective glaze to create a textured layer. The stone-like ceramic bricks are then fired, polished, and produced.

7. The method for preparing ceramic bricks according to claim 6, characterized in that, The firing temperature of the stone-like ceramic bricks is 1180–1210℃.

8. The method for preparing ceramic bricks according to claim 6, characterized in that, The specific gravity of the protective glaze slurry is 1.88–1.90 mg / L.

9. The method for preparing ceramic bricks according to claim 6, characterized in that, The specific gravity of the base glaze slurry is 1.88 to 1.90 mg / L.

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