Preparation method of porcelain antique tile for reducing surface prickly heat

Abstract

The present invention provides a method for preparing porcelain antique tiles that reduces the occurrence of surface prickly heat, and relates to the technical field of antique tile preparation methods. The method comprises the steps of (1) preparing a top glaze; (2) applying the top glaze; (3) applying an antique protective glaze; and (4) low-temperature fast firing. The present invention solves the problem of prickly heat on the brick surface by adjusting the top glaze formula and combining it with the existing antique protective glaze. By increasing the amount of quartz in the top glaze, increasing the SiO2 content, and increasing the firing temperature of the top glaze, the generation of small prickly heat caused by premature melting and sealing of the top glaze during early exhaust is reduced. The firing temperature of the top glaze is adjusted by appropriately increasing the amount of talc used to match the production firing temperature; the amount of nepheline used is reduced to adjust the thermal expansion coefficient to match the production brick shape; and barium carbonate is added to introduce BaO. BaO increases the viscosity of the glaze at low temperatures, making it difficult for gas in the brick to be discharged, thereby further reducing the occurrence of prickly heat. The firing temperature range is wide and suitable for a low-temperature fast firing environment.

Description

Technical Field

[0001] The invention relates to the technical field of antique brick preparation methods, in particular to a preparation method of porcelain antique bricks capable of reducing the generation of prickly heat on the surface. Background Art

[0002] Antique tiles are a type of glazed ceramic tile with a base made of porcelain stoneware (with a water absorption rate of approximately 3%) or stoneware (with a water absorption rate of approximately 8%). Used for building walls and floors, they have a pattern and texture that resembles the effect of stone veneer after long-lasting use, earning them the industry's abbreviation for antique tiles. Antique tiles are not a product of my country's building ceramics industry, but rather an import from abroad. Evolved from glazed tiles, they are essentially glazed porcelain tiles. Compared to ordinary glazed tiles, they differ primarily in the color of the glaze. Antique tiles are ordinary ceramic tiles and are essentially the same as porcelain tiles. The only difference is that during the firing process, antique tiles are aged to mimic past styles. They are essentially glazed porcelain tiles, captivating visitors with their unique, classic charm. To reflect the vicissitudes of time and the weight of history, antique tiles create a nostalgic atmosphere through style, color, and pattern. Antique tiles are made from pure clay fired and then treated with a "watering" process to achieve a bluish-gray color. Unlike common antique tiles (such as porcelain tiles, vitrified tiles, and ancient building blue bricks), they offer a simple, elegant, calm, rustic, natural, and tranquil aesthetic. They are breathable, absorbent, antioxidant, and air-purifying, making them an ideal decorative material for walls and pavements. With rising living standards, consumers are demanding higher standards for decorative materials in modern architecture, preferring more personalized, refined, and artistically designed products. Antique tiles are primarily used for interior and exterior decoration. As their scope of use and user demographics expand, demands for features like anti-slip, wear resistance, and light-shifting properties are evolving, leading to the development of a range of special features and aesthetically pleasing antique tiles. Unlike polished tiles, which require no polishing, antique tiles reduce light reflection, preventing light pollution while providing a more comfortable, plain, and simple visual experience. They complement a variety of young decorating styles. Therefore, antique brick products are becoming more and more popular among consumers.

[0003] The patent (CN112390529A) discloses a matte porcelain antique tile and its manufacturing method, which provides a method for preparing the glaze of the matte porcelain antique tile. The SiO2 content in the glaze is relatively high, reaching 62.33%, and the total content of K2O, Na2O and MgO alkali metals is relatively low. The overall firing temperature is relatively high, the kiln energy consumption is relatively high, and it is not suitable for low-temperature fast firing environment.

[0004] Furthermore, the problem of numerous flaky spots on the glazed surface of antique tiles persists, becoming increasingly apparent as the kiln speeds up, leaving the tiles feeling prickly and impacting the consumer experience. Flaky spots on glazed tiles are caused during the firing process. The bricks in the kiln are not fully oxidized in the early stages of the firing process. During the high-temperature and rapid cooling phases of the firing process, the bricks continue to vent due to the firing system and formulation. At this point, the glaze is already molten and sealed, resulting in high surface tension. This makes it difficult to remove bubbles from the melted glaze, leaving flaky spots on the surface. Summary of the Invention

[0005] The purpose of the present invention is to: under the premise of ensuring that the glaze surface is free of prickly heat, take into account the stability of the brick shape produced by the wide-body kiln and the matching of the firing temperature curve; provide a preparation method for porcelain antique tiles that reduces the generation of surface prickly heat, solve the problem of prickly heat on the glaze surface of antique tiles, increase the SiO2 content in the glaze, increase the glaze firing temperature, and reduce the generation of small prickly heat due to premature melting and sealing of the glaze due to early exhaust; however, as the SiO2 content increases, the glaze firing temperature and thermal expansion coefficient will also increase accordingly, MgO forms a liquid phase at a lower temperature, which can reduce the firing temperature, improve thermal stability, and widen the melting range, so burnt talc is appropriately added to reduce the firing temperature of the glaze; reduce the amount of nepheline used, and reduce the thermal expansion coefficient; and introduce BaO, which increases the viscosity of the glaze at low temperatures, making it difficult for gas in the brick to be discharged, thereby further reducing the generation of prickly heat; and finally optimize the glaze formula that is matched with the existing production of antique glazed tiles without prickly heat, and the glaze color is normal and the production is stable.

[0006] The present invention is achieved through the following technical solutions:

[0007] The present invention provides a method for preparing a porcelain antique tile capable of reducing the occurrence of prickly heat on the surface, comprising the following steps:

[0008] (1) Preparation of the top glaze: The top glaze comprises, by weight, 7-9 parts of kaolin, 6-10 parts of barium carbonate, 33-38 parts of albite, 31-33 parts of quartz, 3-5 parts of calcined talc, 12-14 parts of aluminum oxide, and 8-10 parts of zirconium silicate; the components constituting the top glaze are weighed, mixed uniformly, and ball-milled in a ball mill, and the residue is 0.35-0.5 wt% after passing through a 325-mesh sieve, and aged for 16-22 hours to obtain the top glaze;

[0009] (2) Applying glaze: taking the glaze, applying glaze on the brick to obtain a glazed brick; the glaze specific gravity is controlled at 1.85-1.89, the flow rate is controlled at 25-31s, and the glaze amount is controlled at 370-390g / m 2 ;

[0010] (3) Applying antique protective glaze: Apply antique protective glaze on the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.45-1.50, and the glaze amount is 260-275g / m 2 ;

[0011] (4) Low-temperature fast firing: The bricks to be fired are fired, the firing temperature is controlled at 1135-1165°C, and the firing time is controlled at 41-48 minutes.

[0012] Furthermore, in the step (1), the glaze comprises, by weight, 8 to 9 parts of kaolin, 8 to 10 parts of barium carbonate, 35 to 38 parts of albite, 32 to 33 parts of quartz, 4 to 5 parts of calcined talc, 13 to 14 parts of aluminum oxide, and 9 to 10 parts of zirconium silicate; the components constituting the glaze are weighed, mixed evenly, put into a ball mill, and 0.4 to 0.5 wt% of the residue is passed through a 325-mesh sieve, and aged for 18 to 22 hours to obtain the glaze.

[0013] Furthermore, in step (1), the raw materials of the glaze include the following chemical components by weight percentage: SiO2: 58-62%, Al2O3: 16-19%, BaO: 5%-7%, ZrO2: 4%-6%, Na2O: 3%-6%, MgO: 3%-6%, K2O: 0.5%-1.5%, CaO: 0.5%-1.5%, and the sum of the mass percentages of the chemical components is 100%.

[0014] Furthermore, in the step (2), the glaze is taken and applied on the brick to obtain a glazed brick; the glaze specific gravity is controlled at 1.86 to 1.89, the flow rate is controlled at 28 to 31 seconds, and the glaze amount is controlled at 380 to 390 g / m 2 .

[0015] Furthermore, in the step (2), the method of applying the glaze is bell-jar glazing.

[0016] Furthermore, in the step (3), an antique protective glaze is applied to the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.47 to 1.50, and the glaze amount is 265 to 275 g / m 2 .

[0017] Furthermore, in step (3), the raw materials of the antique protective glaze include the following chemical components by weight percentage: SiO2: 42~46%, Al2O3: 16~19%, CaO: 5%~9%, K2O: 2%~5%, SrO: 2.5%~5.5%, ZnO: 2.5%~5%, MgO: 3%~5%, BaO: 2%~5%, Na2O: 1.5%~3%, and the sum of the mass percentages of the chemical components is 100%.

[0018] Furthermore, the method of applying the antique protective glaze in step (3) is spraying the glaze, using two nozzles with a pore size of 0.62 mm and four nozzles with a pore size of 0.72 mm.

[0019] Furthermore, in the step (4), the brick to be fired is fired, the firing temperature is controlled at 1145-1165° C., and the firing time is controlled at 43-48 minutes.

[0020] Furthermore, in the step (4), the bricks to be fired are fired, and the negative pressure is increased by increasing the exhaust fan pressure in the front temperature zone, so that the pressure in the front temperature zone drops from -30Pa to -60Pa; in the medium temperature zone, when the glaze begins to melt, the zero pressure is controlled to be in the medium temperature zone by adjusting the fire baffle.

[0021] The present invention discloses a preparation method for a porcelain antique tile that reduces the occurrence of surface prickly heat. The method solves the problem of prickly heat on the tile surface by adjusting the top glaze formula and combining it with an existing antique protective glaze. The method increases the amount of quartz used in the top glaze, improves the SiO2 content, and increases the firing temperature of the top glaze to reduce the occurrence of small prickly heat caused by premature melting and sealing of the top glaze due to exhaust in the early stage. The method also appropriately increases the amount of talc used to adjust the top glaze firing temperature to match the production firing temperature. The method also reduces the amount of nepheline used to adjust the thermal expansion coefficient to match the production brick shape. The method also introduces barium carbonate (BaO), which increases the viscosity of the glaze at low temperatures, making it difficult for gases in the brick to be discharged, thereby further reducing the occurrence of prickly heat. The method has a wide firing temperature range and is suitable for a low-temperature, fast-firing environment.

[0022] The invention discloses a preparation method of a porcelain antique tile capable of reducing the generation of surface prickly heat, optimizes the formula of the antique protective glaze, and simultaneously introduces alkaline oxides with strong fluxing properties, such as BaO, SrO, and ZnO, into the formula, thereby reducing the initial melting temperature and high-temperature viscosity of the glaze, being beneficial to the growth of crystals, making it easy to form crystals, and thus improving the hardness and wear resistance of the glaze surface; wherein ZnO greatly reduces the surface tension of the glaze and increases the wettability of the glaze, which are beneficial to the filling of the glass phase into the gaps in the glaze that are not completely melted, thereby improving the flatness of the glaze surface and further improving the wear resistance of the glaze. Pollution, αAl2O3 has relatively few crystal interfaces, and the aluminum atoms and oxygen atoms are arranged in a hexagonal closest form in space. This arrangement is very dense and stable, with high hardness, regular particle shape, and smooth surface, which further improves the hardness of the glaze. Generally, polished tiles have high hardness and high wear resistance, and antique tiles are not as good as polished tiles in hardness and wear resistance. This application improves the glaze formula and optimizes the antique protective glaze formula to make the hardness and wear resistance of antique tiles equivalent to those of polished tiles, which can effectively solve the problem of prickly heat on the surface of antique tiles.

[0023] The present invention provides a preparation method for porcelain antique tiles for reducing the occurrence of prickly heat on the surface. The method increases the negative pressure by increasing the pressure of a smoke exhaust fan in a front temperature zone, thereby enhancing the oxidation strength of the bricks. The method also helps oxidize and exhaust gas by adjusting a fire baffle to control the zero pressure position near a medium temperature zone, thereby further reducing prickly heat on the glaze surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 This is a picture of the product prepared in Example 1 of the present invention;

[0025] Figure 2 This is a picture of the product prepared in Comparative Example 1. DETAILED DESCRIPTION

[0026] Any feature disclosed in this specification (including any appended claims and abstract), unless otherwise stated, may be replaced by other equivalent or similar features. That is, unless otherwise stated, each feature is only an example of a series of equivalent or similar features.

[0027] The invention discloses a preparation method of a porcelain antique tile capable of reducing the generation of prickly heat on the surface. The method comprises controlling the raw material composition of a surface glaze by weight percentage. The raw materials of the surface glaze comprise the following chemical components by weight percentage: SiO2: 58-62%, Al2O3: 16-19%, BaO: 5-7%, ZrO2: 4-6%, Na2O: 3-6%, MgO: 3-6%, K2O: 0.5-1.5%, and CaO: 0.5-1.5%, wherein the sum of the weight percentages of the chemical components is 100%.

[0028] Example 1

[0029] A method for preparing a porcelain antique tile for reducing the occurrence of prickly heat on the surface comprises the following steps:

[0030] (1) Preparation of glaze: The glaze comprises, by weight, 7 parts of kaolin, 6 parts of barium carbonate, 33 parts of albite, 31 parts of quartz, 3 parts of calcined talc, 12 parts of aluminum oxide, and 8 parts of zirconium silicate; the components constituting the glaze are weighed and mixed uniformly, placed in a ball mill, and 39% of water, 0.18% of methyl, and 0.32% of trimer are added, ball milled, and 0.35% of the residue is passed through a 325-mesh sieve, and aged for 16 hours to obtain the glaze;

[0031] (2) Applying glaze: taking the glaze, applying the glaze on the brick blank, the glaze applying method is bell jar glazing, and obtaining the glazed brick blank; the glaze specific gravity is controlled at 1.85, the flow rate is controlled at 25s, and the glaze amount is controlled at 370g / m 2 ;

[0032] (3) Applying antique protective glaze: Applying antique protective glaze on the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.45, and the glaze amount is 260g / m 2 ;

[0033] The method of applying antique protective glaze is spraying glaze, using two nozzles with a 0.62mm aperture and four nozzles with a 0.72mm aperture to spray glaze;

[0034] The raw materials of the antique protective glaze include the following chemical components by weight percentage: SiO2: 46%, Al2O3: 19%, CaO: 9%, K2O: 5%, SrO: 5.5%, ZnO: 5%, MgO: 5%, BaO: 4%, Na2O: 1.5%, and the sum of the mass percentages of the chemical components is 100%;

[0035] (4) Low-temperature fast firing: The bricks to be fired are fired at a temperature of 1135°C and a firing time of 41 minutes; cooled, the finished product is taken out, the glossiness of the glaze of the finished product, the ink absorption of the glaze, other items of the finished product are tested, and the condition of prickly heat on the glaze surface is observed.

[0036] Example 2

[0037] A method for preparing a porcelain antique tile for reducing the occurrence of prickly heat on the surface comprises the following steps:

[0038] (1) Preparation of glaze: The glaze comprises, by weight, 9 parts of kaolin, 10 parts of barium carbonate, 38 parts of albite, 33 parts of quartz, 5 parts of calcined talc, 14 parts of aluminum oxide, and 10 parts of zirconium silicate; the components constituting the glaze are weighed and mixed uniformly, placed in a ball mill, and 39% of water, 0.18% of methyl, and 0.32% of trimer are added, ball milled, passed through a 325-mesh sieve, and the residue is 0.5 wt %. The mixture is aged for 22 hours to obtain the glaze;

[0039] (2) Applying glaze: taking the glaze, applying the glaze on the brick blank, the glaze applying method is bell jar glazing, and obtaining the glazed brick blank; the glaze specific gravity is controlled at 1.89, the flow rate is controlled at 31s, and the glaze amount is controlled at 390g / m 2 ;

[0040] (3) Applying antique protective glaze: Apply antique protective glaze on the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.50, and the glaze amount is 275g / m 2 ;

[0041] The method of applying antique protective glaze is spraying glaze, using two nozzles with a 0.62mm aperture and four nozzles with a 0.72mm aperture to spray glaze;

[0042] The raw materials of the antique protective glaze include the following chemical components by weight percentage: SiO2: 46%, Al2O3: 19%, CaO: 9%, K2O: 5%, SrO: 5.5%, ZnO: 5%, MgO: 5%, BaO: 4%, Na2O: 1.5%, and the sum of the mass percentages of the chemical components is 100%;

[0043] (4) Low-temperature fast firing: The bricks to be fired are fired at a temperature of 1165°C and a firing time of 48 minutes; cooled, the finished product is taken out, the glossiness of the glaze of the finished product, the ink absorption of the glaze, other items of the finished product are tested, and the prickly heat condition of the glaze is observed.

[0044] Example 3

[0045] A method for preparing a porcelain antique tile for reducing the occurrence of prickly heat on the surface comprises the following steps:

[0046] (1) Preparation of top glaze: The top glaze comprises, by weight, 8 parts of kaolin, 8 parts of barium carbonate, 35 parts of albite, 32 parts of quartz, 4 parts of calcined talc, 13 parts of aluminum oxide, and 9 parts of zirconium silicate; the components constituting the top glaze are weighed and mixed uniformly, placed in a ball mill, and 39% of water, 0.18% of methyl, and 0.32% of trimer are added, ball milled, and 0.4 wt% of the residue is passed through a 325-mesh sieve, and aged for 18 hours to obtain the top glaze;

[0047] (2) Applying glaze: taking the glaze, applying the glaze on the brick blank, the glaze applying method is bell jar glazing, and obtaining the glazed brick blank; the glaze specific gravity is controlled at 1.86, the flow rate is controlled at 28s, and the glaze amount is controlled at 380g / m 2 ;

[0048] (3) Applying antique protective glaze: Apply antique protective glaze on the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.47, and the glaze amount is 265g / m 2 ;

[0049] The method of applying antique protective glaze is spraying glaze, using two nozzles with a 0.62mm aperture and four nozzles with a 0.72mm aperture to spray glaze;

[0050] The raw materials of the antique protective glaze include the following chemical components by weight percentage: SiO2: 46%, Al2O3: 19%, CaO: 9%, K2O: 5%, SrO: 5.5%, ZnO: 5%, MgO: 5%, BaO: 4%, Na2O: 1.5%, and the sum of the mass percentages of the chemical components is 100%;

[0051] (4) Low-temperature fast firing: The bricks to be fired are fired at a temperature of 1145°C and a firing time of 43 minutes; cooled, the finished product is taken out, the glossiness of the glaze of the finished product, the ink absorption of the glaze, other items of the finished product are tested, and the prickly heat condition of the glaze is observed.

[0052] Example 4

[0053] A method for preparing a porcelain antique tile for reducing the occurrence of prickly heat on the surface comprises the following steps:

[0054] (1) Preparation of glaze: The glaze comprises, by weight, 8 parts of kaolin, 8 parts of barium carbonate, 35 parts of albite, 31 parts of quartz, 5 parts of calcined talc, 13 parts of aluminum oxide, and 9 parts of zirconium silicate; the components constituting the glaze are weighed and mixed uniformly, placed in a ball mill, and 39% of water, 0.18% of methyl, and 0.32% of trimer are added, ball milled, and 0.4 wt% of the residue is passed through a 325-mesh sieve, and aged for 20 hours to obtain the glaze;

[0055] (2) Applying glaze: Take the glaze and apply it on the brick blank. The glaze application method is bell jar glazing to obtain a glazed brick blank; the glaze specific gravity is controlled at 1.88, the flow rate is controlled at 29s, and the glaze amount is controlled at 385g / m 2 ;

[0056] (3) Applying antique protective glaze: Applying antique protective glaze on the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.48, and the glaze amount is 270g / m 2 ;

[0057] The method of applying antique protective glaze is spraying glaze, using two nozzles with a 0.62mm aperture and four nozzles with a 0.72mm aperture to spray glaze;

[0058] The raw materials of the antique protective glaze include the following chemical components by weight percentage: SiO2: 46%, Al2O3: 19%, CaO: 9%, K2O: 5%, SrO: 5.5%, ZnO: 5%, MgO: 5%, BaO: 4%, Na2O: 1.5%, and the sum of the mass percentages of the chemical components is 100%;

[0059] (4) Low-temperature fast firing: The bricks to be fired are fired at a temperature of 1160°C and a firing time of 47 minutes; cooled, the finished product is taken out, the glossiness of the glaze of the finished product, the ink absorption of the glaze, other items of the finished product are tested, and the prickly heat condition of the glaze is observed.

[0060] Example 5

[0061] A method for preparing a porcelain antique tile for reducing the occurrence of prickly heat on the surface comprises the following steps:

[0062] (1) Preparation of glaze: The glaze comprises, by weight, 8 parts of kaolin, 6 parts of barium carbonate, 35 parts of albite, 33 parts of quartz, 5 parts of calcined talc, 13 parts of aluminum oxide, and 9 parts of zirconium silicate; the components constituting the glaze are weighed and mixed uniformly, placed in a ball mill, and 39% of water, 0.18% of methyl, and 0.32% of trimer are added, ball milled, and 0.4 wt% of the residue is passed through a 325-mesh sieve, and aged for 20 hours to obtain the glaze;

[0063] (2) Applying glaze: Take the glaze and apply it on the brick blank. The glaze application method is bell jar glazing to obtain a glazed brick blank; the glaze specific gravity is controlled at 1.88, the flow rate is controlled at 29s, and the glaze amount is controlled at 385g / m 2 ;

[0064] (3) Applying antique protective glaze: Applying antique protective glaze on the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.48, and the glaze amount is 270g / m 2 ;

[0065] The method of applying antique protective glaze is spraying glaze, using two nozzles with a 0.62mm aperture and four nozzles with a 0.72mm aperture to spray glaze;

[0066] The raw materials of the antique protective glaze include the following chemical components by weight percentage: SiO2: 46%, Al2O3: 19%, CaO: 9%, K2O: 5%, SrO: 5.5%, ZnO: 5%, MgO: 5%, BaO: 4%, Na2O: 1.5%, and the sum of the mass percentages of the chemical components is 100%;

[0067] (4) Low-temperature fast firing: The bricks to be fired are fired at a temperature of 1160°C and a firing time of 47 minutes; cooled, the finished product is taken out, the glossiness of the glaze of the finished product, the ink absorption of the glaze, other items of the finished product are tested, and the prickly heat condition of the glaze is observed.

[0068] Example 6

[0069] A method for preparing a porcelain antique tile for reducing the occurrence of prickly heat on the surface comprises the following steps:

[0070] (1) Preparation of glaze: The glaze comprises, by weight, 8 parts of kaolin, 10 parts of barium carbonate, 35 parts of albite, 31 parts of quartz, 3 parts of calcined talc, 13 parts of aluminum oxide, and 9 parts of zirconium silicate; the components constituting the glaze are weighed and mixed uniformly, placed in a ball mill, and 39% of water, 0.18% of methyl, and 0.32% of trimer are added, ball milled, and 0.4 wt% of the residue is passed through a 325-mesh sieve, and aged for 20 hours to obtain the glaze;

[0071] (2) Applying glaze: Take the glaze and apply it on the brick blank. The glaze application method is bell jar glazing to obtain a glazed brick blank; the glaze specific gravity is controlled at 1.88, the flow rate is controlled at 29s, and the glaze amount is controlled at 385g / m 2 ;

[0072] (3) Applying antique protective glaze: Applying antique protective glaze on the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.48, and the glaze amount is 270g / m 2 ;

[0073] The method of applying antique protective glaze is spraying glaze, using two nozzles with a 0.62mm aperture and four nozzles with a 0.72mm aperture to spray glaze;

[0074] The raw materials of the antique protective glaze include the following chemical components by weight percentage: SiO2: 46%, Al2O3: 19%, CaO: 9%, K2O: 5%, SrO: 5.5%, ZnO: 5%, MgO: 5%, BaO: 4%, Na2O: 1.5%, and the sum of the mass percentages of the chemical components is 100%;

[0075] (4) Low-temperature fast firing: The bricks to be fired are fired at a temperature of 1160°C and a firing time of 47 minutes; cooled, the finished product is taken out, the glossiness of the glaze of the finished product, the ink absorption of the glaze, other items of the finished product are tested, and the prickly heat condition of the glaze is observed.

[0076] Example 7

[0077] A method for preparing a porcelain antique tile for reducing the occurrence of prickly heat on the surface comprises the following steps:

[0078] (1) Preparation of glaze: The glaze comprises, by weight, 8 parts of kaolin, 10 parts of barium carbonate, 35 parts of albite, 31 parts of quartz, 3 parts of calcined talc, 13 parts of aluminum oxide, and 9 parts of zirconium silicate; the components constituting the glaze are weighed and mixed uniformly, placed in a ball mill, and 39% of water, 0.18% of methyl, and 0.32% of trimer are added, ball milled, and 0.4 wt% of the residue is passed through a 325-mesh sieve, and aged for 20 hours to obtain the glaze;

[0079] (2) Applying glaze: Take the glaze and apply it on the brick blank. The glaze application method is bell jar glazing to obtain a glazed brick blank; the glaze specific gravity is controlled at 1.88, the flow rate is controlled at 29s, and the glaze amount is controlled at 385g / m 2 ;

[0080] (3) Applying antique protective glaze: Applying antique protective glaze on the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.48, and the glaze amount is 270g / m 2 ;

[0081] The method of applying antique protective glaze is spraying glaze, using two nozzles with a 0.62mm aperture and four nozzles with a 0.72mm aperture to spray glaze;

[0082] The antique protective glaze used is a commercial product and does not contain alkaline oxides with strong flux properties such as BaO, SrO, and ZnO.

[0083] (4) Low-temperature fast firing: The bricks to be fired are fired at a temperature of 1160°C and a firing time of 47 minutes; cooled, the finished product is taken out, the glossiness of the glaze of the finished product, the ink absorption of the glaze, other items of the finished product are tested, and the prickly heat condition of the glaze is observed.

[0084] Comparative Example 1

[0085] A method for preparing a porcelain antique tile for reducing the occurrence of prickly heat on the surface comprises the following steps:

[0086] (1) Preparation of glaze: The glaze comprises, by weight, 8 parts of kaolin, 14 parts of nepheline, 35 parts of albite, 23 parts of quartz, 3 parts of calcined talc, 13 parts of alumina, and 9 parts of zirconium silicate; the components constituting the glaze are weighed and mixed uniformly, placed in a ball mill, and 39% of water, 0.18% of methyl, and 0.32% of trimer are added, ball milled, and 0.4 wt% of the residue is passed through a 325-mesh sieve, and aged for 20 hours to obtain the glaze;

[0087] (2) Applying glaze: Take the glaze and apply it on the brick blank. The glaze application method is bell jar glazing to obtain a glazed brick blank; the glaze specific gravity is controlled at 1.88, the flow rate is controlled at 29s, and the glaze amount is controlled at 385g / m 2 ;

[0088] (3) Applying antique protective glaze: Applying antique protective glaze on the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.48, and the glaze amount is 270g / m 2 ;

[0089] The method of applying antique protective glaze is spraying glaze, using two nozzles with a 0.62mm aperture and four nozzles with a 0.72mm aperture to spray glaze;

[0090] The raw materials of the antique protective glaze include the following chemical components by weight percentage: SiO2: 46%, Al2O3: 19%, CaO: 9%, K2O: 5%, SrO: 5.5%, ZnO: 5%, MgO: 5%, BaO: 4%, Na2O: 1.5%, and the sum of the mass percentages of the chemical components is 100%;

[0091] (4) Low-temperature fast firing: The bricks to be fired are fired at a temperature of 1160°C and a firing time of 47 minutes; cooled, the finished product is taken out, the glossiness of the glaze of the finished product, the ink absorption of the glaze, other items of the finished product are tested, and the prickly heat condition of the glaze is observed.

[0092] Comparative Example 2

[0093] A method for preparing a porcelain antique tile for reducing the occurrence of prickly heat on the surface comprises the following steps:

[0094] (1) Preparation of glaze: The glaze comprises, by weight, 8 parts of kaolin, 12 parts of nepheline, 35 parts of albite, 29 parts of quartz, 3 parts of calcined talc, 13 parts of alumina, and 9 parts of zirconium silicate; the components constituting the glaze are weighed and mixed uniformly, placed in a ball mill, and 39% of water, 0.18% of methyl, and 0.32% of trimer are added, ball milled, and 0.4 wt% of the residue is passed through a 325-mesh sieve, and aged for 20 hours to obtain the glaze;

[0095] (2) Applying glaze: Take the glaze and apply it on the brick blank. The glaze application method is bell jar glazing to obtain a glazed brick blank; the glaze specific gravity is controlled at 1.88, the flow rate is controlled at 29s, and the glaze amount is controlled at 385g / m 2 ;

[0096] (3) Applying antique protective glaze: Applying antique protective glaze on the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.48, and the glaze amount is 270g / m 2 ;

[0097] The method of applying antique protective glaze is spraying glaze, using two nozzles with a 0.62mm aperture and four nozzles with a 0.72mm aperture to spray glaze;

[0098] The raw materials of the antique protective glaze include the following chemical components by weight percentage: SiO2: 46%, Al2O3: 19%, CaO: 9%, K2O: 5%, SrO: 5.5%, ZnO: 5%, MgO: 5%, BaO: 4%, Na2O: 1.5%, and the sum of the mass percentages of the chemical components is 100%;

[0099] (4) Low-temperature fast firing: The bricks to be fired are fired at a temperature of 1160°C and a firing time of 47 minutes; cooled, the finished product is taken out, the glossiness of the glaze of the finished product, the ink absorption of the glaze, other items of the finished product are tested, and the prickly heat condition of the glaze is observed.

[0100] Comparative Example 3

[0101] A method for preparing a porcelain antique tile for reducing the occurrence of prickly heat on the surface comprises the following steps:

[0102] (1) Preparation of glaze: The glaze comprises, by weight, 8 parts of kaolin, 10 parts of nepheline, 2 parts of barium carbonate, 35 parts of albite, 29 parts of quartz, 3 parts of calcined talc, 13 parts of aluminum oxide, and 9 parts of zirconium silicate; the components constituting the glaze are weighed, mixed uniformly, placed in a ball mill, and 39% of water, 0.18% of methyl, and 0.32% of trimer are added, ball milled, and 0.4 wt% of the residue is passed through a 325-mesh sieve, and aged for 20 hours to obtain the glaze;

[0103] (2) Applying glaze: Take the glaze and apply it on the brick blank. The glaze application method is bell jar glazing to obtain a glazed brick blank; the glaze specific gravity is controlled at 1.88, the flow rate is controlled at 29s, and the glaze amount is controlled at 385g / m 2 ;

[0104] (3) Applying antique protective glaze: Applying antique protective glaze on the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.48, and the glaze amount is 270g / m 2 ;

[0105] The method of applying antique protective glaze is spraying glaze, using two nozzles with a 0.62mm aperture and four nozzles with a 0.72mm aperture to spray glaze;

[0106] The raw materials of the antique protective glaze include the following chemical components by weight percentage: SiO2: 46%, Al2O3: 19%, CaO: 9%, K2O: 5%, SrO: 5.5%, ZnO: 5%, MgO: 5%, BaO: 4%, Na2O: 1.5%, and the sum of the mass percentages of the chemical components is 100%;

[0107] (4) Low-temperature fast firing: The bricks to be fired are fired at a temperature of 1160°C and a firing time of 47 minutes; cooled, the finished product is taken out, the glossiness of the glaze of the finished product, the ink absorption of the glaze, other items of the finished product are tested, and the prickly heat condition of the glaze is observed.

[0108] The parameters of the porcelain antique tiles obtained in Examples 1-6 and Comparative Examples 1-3 are shown in Table 1 below:

[0109] Table 1

[0110]

[0111] It can be seen from Comparative Example 1, Comparative Example 2 and Example 4 that with the increase of the amount of quartz, the number of prickly heat on the brick surface has changed from many to a small amount and then to none. This is because with the increase of quartz, the SiO2 content in the glaze also increases, and the firing temperature of the glaze becomes higher, which reduces the small prickly heat caused by the premature melting and sealing of the exhaust glaze in the early stage.

[0112] It can be seen from Comparative Example 3 and Example 4 that with the increase in the amount of barium carbonate added, the amount of prickly heat on the brick surface has decreased from a small amount to none. This is because with the increase in barium carbonate, the BaO content in the glaze also increases. BaO increases the viscosity of the glaze at low temperatures, making it difficult for the gas in the brick to be discharged, thereby further reducing the occurrence of prickly heat.

[0113] As can be seen from Comparative Examples 2, 3, and Example 4, as the amount of quartz increases, the number of prickly heat on the brick surface decreases from a small amount to none. This is because as the amount of quartz increases, the SiO2 content in the glaze also increases, and the firing temperature of the glaze becomes higher, which reduces the small prickly heat caused by the premature melting and sealing of the glaze during the early exhaust process. The glaze in Comparative Example 1 absorbs ink severely, and the firing temperature of the glaze is too high. The amount of calcined talc was appropriately increased, and the firing temperature of the glaze was adjusted to match the production. The finished brick shape of Comparative Example 1 is warped beyond the standard. This is because the increase in the SiO2 content in the glaze increases the thermal expansion coefficient of the glaze, resulting in warping of the finished brick shape.

[0114] The invention discloses a preparation method of a porcelain antique tile capable of reducing the generation of surface prickly heat, optimizes the formula of the antique protective glaze, and simultaneously introduces alkaline oxides with strong fluxing properties, such as BaO, SrO, and ZnO, into the formula, thereby reducing the initial melting temperature and high-temperature viscosity of the glaze, being beneficial to the growth of crystals, making it easy to form crystals, and thus improving the hardness and wear resistance of the glaze surface; wherein ZnO greatly reduces the surface tension of the glaze and increases the wettability of the glaze, which are beneficial to the filling of the glass phase into the gaps in the glaze that are not completely melted, thereby improving the flatness of the glaze surface and further improving the wear resistance of the glaze. Pollution, αAl2O3 has relatively few crystal interfaces, and the aluminum atoms and oxygen atoms are arranged in a hexagonal closest form in space. This arrangement is very dense and stable, with high hardness, regular particle shape, and smooth surface, which further improves the hardness of the glaze. Generally, polished tiles have high hardness and high wear resistance, and antique tiles are not as good as polished tiles in hardness and wear resistance. This application improves the glaze formula and optimizes the antique protective glaze formula to make the hardness and wear resistance of antique tiles equivalent to those of polished tiles, which can effectively solve the problem of prickly heat on the surface of antique tiles.

[0115] The present invention discloses a preparation method for a porcelain antique tile that reduces the occurrence of surface prickly heat. The method solves the problem of prickly heat on the tile surface by adjusting the top glaze formula and combining it with an existing antique protective glaze. The method increases the amount of quartz used in the top glaze, improves the SiO2 content, and increases the firing temperature of the top glaze to reduce the occurrence of small prickly heat caused by premature melting and sealing of the top glaze due to exhaust in the early stage. The method also appropriately increases the amount of talc used to adjust the top glaze firing temperature to match the production firing temperature. The method also reduces the amount of nepheline used to adjust the thermal expansion coefficient to match the production brick shape. The method also introduces barium carbonate (BaO), which increases the viscosity of the glaze at low temperatures, making it difficult for gases in the brick to be discharged, thereby further reducing the occurrence of prickly heat. The method has a wide firing temperature range and is suitable for a low-temperature, fast-firing environment.

[0116] The present invention provides a method for preparing porcelain antique tiles for reducing the occurrence of surface prickly heat. In the above embodiment, the size of the porcelain antique tiles is conventional 800 mm*800 mm, and conventional low-temperature fast firing can effectively reduce prickly heat on the glazed surface. For extra-large tiles with a size within the range of 1620 mm*3240 mm, the negative pressure can be increased by increasing the pressure of the smoke exhaust fan in the front temperature zone, thereby enhancing the oxidation strength of the brick blank. By adjusting the fire baffle to control the zero pressure position near the medium temperature zone, oxidation exhaust is facilitated, thereby further reducing prickly heat on the glazed surface.

[0117] The foregoing descriptions of specific exemplary embodiments of the present invention are for purposes of illustration and description. These descriptions are not intended to limit the invention to the precise forms disclosed, and it is apparent that many variations and modifications are possible in light of the foregoing teachings. The exemplary embodiments have been selected and described for the purpose of explaining the specific principles of the invention and their practical application, thereby enabling those skilled in the art to realize and utilize a variety of exemplary embodiments of the invention and various options and modifications. The scope of the invention is intended to be defined by the claims and their equivalents.

Claims

1. A method for preparing a porcelain antique tile that reduces the generation of prickly heat on the surface, characterized in that: The following steps are involved: (1) Preparation of top glaze: The top glaze comprises, by weight, 7-9 parts of kaolin, 6-10 parts of barium carbonate, 33-38 parts of albite, 31-33 parts of quartz, 3-5 parts of calcined talc, 12-14 parts of aluminum oxide, and 8-10 parts of zirconium silicate; the components constituting the top glaze are weighed, mixed uniformly, and ball-milled in a ball mill, and the residue is 0.35-0.5 wt% after passing through a 325-mesh sieve, and aged for 16-22 hours to obtain the top glaze; (2) applying glaze: taking the glaze, applying glaze on the brick to obtain a glazed brick; the glaze specific gravity is controlled at 1.85-1.89, the flow rate is controlled at 25-31s, and the glaze amount is controlled at 370-390g / m2; (3) Applying antique protective glaze: applying antique protective glaze on the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.45-1.50, and the glaze amount is 260-275 g / m2; the raw materials of the antique protective glaze include the following chemical components by weight percentage: SiO2: 42-46%, Al2O3: 16-19%, CaO: 5%-9%, K2O: 2%-5%, SrO: 2.5%-5.5%, ZnO: 2.5%-5%, MgO: 3%-5%, BaO: 2%-5%, Na2O: 1.5%-3%, and the sum of the mass percentages of the chemical components is 100%; (4) Low-temperature fast firing: The bricks to be fired are fired, the firing temperature is controlled at 1135-1165°C, and the firing time is controlled at 41-48 minutes.

2. The method for preparing a porcelain antique tile for reducing the generation of surface prickly heat according to claim 1, characterized in that: In the step (1), the glaze comprises, by weight, 8 to 9 parts of kaolin, 8 to 10 parts of barium carbonate, 35 to 38 parts of albite, 32 to 33 parts of quartz, 4 to 5 parts of calcined talc, 13 to 14 parts of aluminum oxide, and 9 to 10 parts of zirconium silicate; the components constituting the glaze are weighed, mixed evenly, and ball-milled in a ball mill, and sieved through a 325-mesh sieve to obtain a residue of 0.4 to 0.5 wt %, and aged for 18 to 22 hours to obtain the glaze.

3. The method for preparing a porcelain antique tile for reducing the generation of surface prickly heat according to claim 1, characterized in that: In the step (1), the raw materials of the glaze include the following chemical components in weight percentage: SiO2: 58% to 62%, Al2O3: 16% to 19%, BaO: 5% to 7%, ZrO2: 4% to 6%, Na2O: 3% to 6%, MgO: 3% to 6%, K2O: 0.5% to 1.5%, CaO: 0.5% to 1.5%, and the sum of the weight percentages of the chemical components is 100%.

4. The method for preparing a porcelain antique tile for reducing the generation of surface prickly heat according to claim 1, characterized in that: In the step (2), the glaze is taken and applied on the brick to obtain a glazed brick; the glaze specific gravity is controlled at 1.86 to 1.89, the flow rate is controlled at 28 to 31 seconds, and the glaze amount is controlled at 380 to 390 g / m2.

5. The method for preparing a porcelain antique tile for reducing the occurrence of surface prickly heat according to claim 1, characterized in that: In the step (2), the method of applying the glaze is bell-jar glazing.

6. The method for preparing a porcelain antique tile for reducing the occurrence of prickly heat on the surface according to claim 1, characterized in that: In the step (3), an antique protective glaze is applied on the glazed brick to obtain a brick to be fired; the specific gravity of the antique protective glaze is controlled at 1.47 to 1.50, and the glaze amount is 265 to 275 g / m2.

7. The method for preparing a porcelain antique tile for reducing the occurrence of surface prickly heat according to claim 1, characterized in that: The method of applying the antique protective glaze in step (3) is spraying the glaze, using two nozzles with a pore size of 0.62 mm and four nozzles with a pore size of 0.72 mm.

8. The method for preparing a porcelain antique tile for reducing the occurrence of surface prickly heat according to claim 1, characterized in that: In the step (4), the brick to be fired is fired, the firing temperature is controlled at 1145-1165° C., and the firing time is controlled at 43-48 minutes.

9. The method for preparing a porcelain antique tile for reducing the occurrence of surface prickly heat according to claim 1, characterized in that: In the step (4), the bricks to be fired are fired, and the negative pressure is increased by increasing the exhaust fan pressure in the front temperature zone, so that the pressure in the front temperature zone drops from -30Pa to -60Pa; in the medium temperature zone, when the glaze begins to melt, the zero pressure is controlled to be in the medium temperature zone by adjusting the fire baffle.

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