Ceramic tile with silk-like glaze effect and preparation method thereof

Abstract

The present invention discloses a ceramic tile with a silk-like glaze effect and a preparation method thereof. The ceramic tile comprises, from bottom to top, a body, a top glaze layer, and a transparent glaze layer, wherein: zinc oxide crystals are distributed between the body and the top glaze layer; the zinc oxide crystals are precipitated from calcined zinc oxide particles laid on the upper surface of the body during the firing process; the raw material components of the top glaze layer include, by weight percentage, SiO2 45-50%, Al2O3 5-10%, ZnO 20-25%, K2O 5-10%, MgO 3-5%, Na2O 1-3%, B2O3 3-5%, Fe2O3 0.1-0.5%, and TiO2 0.2-0.4%. By laying calcined zinc oxide particles on the surface of the body and combining specific raw material components of the top glaze layer, the ceramic tile prepared by the present invention not only feels similar to silk but also visually has the color and texture of silk.

Description

Technical Field

[0001] The invention belongs to the technical field of building ceramics, and particularly relates to a ceramic tile with a silk-like glaze effect and a preparation method thereof. Background Art

[0002] Many designers favor satin-glazed tiles for interior design. Using satin-glazed tiles maximizes the stylish feel of a space in terms of performance, light, touch, and texture. Satin glaze closely replicates the natural 16-degree sheen of real stone, creating a sophisticated, restrained, realistic, and refined finish that perfectly replicates the natural effects of high-end stone. While retaining the authentic luster of high-end tiles, satin glaze avoids highly reflective light pollution, fostering a healthy home experience. Unpolished satin-glazed tiles retain the authentic ceramic glaze, significantly improving their stain resistance and ensuring easy maintenance for a comfortable living experience.

[0003] Currently, there are two main types of satin-glazed tiles on the market. One is made from potassium feldspar, kaolin, quartz, alumina, talc, and zinc oxide. The raw materials are mixed, ball-milled, and sieved to create a satin glaze. The glaze is then applied to the body to form a satin-glazed tile. However, the satin-glazed tile produced by this method only has a satin-like texture in terms of gloss and touch, and visually lacks the color and texture of satin. The other method is to inoculate zinc oxide seeds on a specially prepared crystallization glaze. However, during the high-temperature firing process, the zinc oxide seeds will partially melt into the glaze, resulting in poor crystallization. Moreover, the inoculation of the seeds on the glaze will also have a certain impact on the glaze effect. At the same time, due to the certain fluidity of the glaze during the high-temperature firing process, crystallization in specific locations cannot be guaranteed. Summary of the Invention

[0004] The present invention aims to address at least one of the technical problems existing in the aforementioned prior art. To this end, the present invention provides a ceramic tile with a silk-like glaze effect and a method for preparing the same. The ceramic tile not only feels like silk to the touch but also visually exhibits the color and texture of silk, achieving a realistic silk-like glaze effect.

[0005] In order to solve the above technical problems, the first aspect of the present invention provides a ceramic tile, which includes, from bottom to top, a body, a surface glaze layer and a transparent glaze layer; zinc oxide crystals are distributed between the body and the surface glaze layer, and the zinc oxide crystals are precipitated from calcined zinc oxide particles laid on the upper surface of the body during the firing process; the raw material components of the surface glaze layer include, by weight percentage: SiO2 45-50%, Al2O3 5-10%, ZnO 20-25%, K2O 5-10%, MgO 3-5%, Na2O 1-3%, B2O3 3-5%, Fe2O3 0.1-0.5%, and TiO2 0.2-0.4%.

[0006] Specifically, the present invention lays calcined zinc oxide particles on the surface of the ceramic tile body and combines it with specific glaze layer raw material components to precipitate zinc oxide crystals at specified locations; and by controlling the particle size of the zinc oxide particles to adjust the size of the crystals, perfect crystals are formed on the entire tile surface, thereby achieving a ceramic tile that not only feels like silk, but also visually has the color and texture of silk.

[0007] At the same time, since the zinc oxide particles in the surface glaze layer are small and have a high solubility in the glaze, they are extremely unstable and difficult to form crystal nuclei and precipitate crystal flowers. The present invention greatly increases the concentration of zinc oxide by directly laying zinc oxide particles on the surface of the blank, and even at a higher firing temperature, it cannot be completely melted, thereby forming an ideal crystallization center. The zinc oxide crystal flowers are fan-shaped patterns with a silky luster texture. When regularly arranged zinc oxide crystallization patterns overlap with each other, they can cover the entire glaze surface, thereby achieving a realistic imitation silky thick glaze effect.

[0008] In addition, the present invention controls the raw material components of the surface glaze layer to achieve a better crystallization effect. Studies have found that too much SiO2 will increase the viscosity of the glaze melt and reduce the crystallization rate; too little SiO2 is not conducive to the precipitation of zinc oxide crystals; the Al2O3 content should not be too high, otherwise it will affect the precipitation of zinc oxide crystals; although Na2O is beneficial to promote glaze crystallization, it has a large thermal expansion coefficient. The use of K2O can reduce the thermal expansion coefficient of the glaze and assist in fluxing; and MgO and B2O3 are used to partially replace Na2O, which plays a role in fluxing and promoting crystallization. During the firing process, some components in the surface glaze migrate to the surface layer of the body, and some components in the body also diffuse into the surface glaze. The components of the surface glaze react with the zinc oxide particles, increasing the concentration of zinc oxide. The interaction between the two promotes the precipitation of zinc oxide crystals.

[0009] As a further improvement of the above solution, the average particle size of the calcined zinc oxide particles is 0.2-0.4 mm.

[0010] Specifically, the size of the calcined zinc oxide particles directly determines the size of the crystal flowers. By controlling the zinc oxide particles within a suitable particle size range, the precipitated crystal flowers can have clear textures, be plump and round, and have a realistic silk-like effect.

[0011] As a further improvement of the above solution, the thickness of the glaze layer is 0.5-1 mm.

[0012] Specifically, if the top glaze layer is too thin, the zinc oxide crystals distributed on the body will be small and the glaze effect will be rough; if the glaze layer is too thick, the non-localized crystal nuclei in the top glaze will increase, the crystals will pile up together, and the crystals will appear stacked; when the thickness of the top glaze layer is 0.5-1mm, the crystals will grow fully and the glaze effect will be better.

[0013] As a further improvement of the above solution, the transparent glaze layer is formed by firing a matte transparent glaze, wherein the glossiness of the matte transparent glaze is 12-16°. The matte transparent glaze can obtain a more realistic silk-like glaze effect.

[0014] As a further improvement of the above solution, the raw material components of the surface glaze layer also include 3-5 wt% of a colorant.

[0015] Preferably, the colorant is selected from at least one of CuO, V2O5, CoO, and Ni2O3. By adding coloring oxides, a colorful silk glaze effect can be presented, further enriching the pattern effect of the product.

[0016] A second aspect of the present invention provides a method for preparing the above-mentioned ceramic tile, comprising the following steps:

[0017] (1) First, a layer of powder for preparing a green body is laid in a mold, and then calcined zinc oxide particles are laid, and pressed into shape to obtain a green body with calcined zinc oxide laid on the surface;

[0018] (2) applying a top glaze and a transparent glaze in sequence on the upper surface of the green body to form a top glaze layer and a transparent glaze layer, and firing the glaze to obtain the ceramic tile.

[0019] As a further improvement of the above solution, in step (2), after firing, the transparent glaze layer is also soft-polished.

[0020] As a further improvement of the above solution, in step (2), the sintering atmosphere is an oxidizing atmosphere. A reducing atmosphere is not conducive to the precipitation of zinc oxide crystals or leads to incomplete crystallization, thereby affecting the product effect.

[0021] As a further improvement of the above scheme, in step (2), the sintering temperature regime is: first heating to 1200-1220°C and keeping warm for 30-60 minutes; then cooling to 1100-1150°C and keeping warm for 100-140 minutes; and finally cooling to room temperature.

[0022] Specifically, at the highest firing temperature of 1200-1220°C, the glaze is in a molten state; when the temperature drops to 1100-1150°C, zinc oxide crystals precipitate from the glaze melt and are kept warm for a certain period of time to allow the crystals to grow and form crystal flowers.

[0023] Compared with the prior art, the above technical solution of the present invention has at least the following technical effects or advantages:

[0024] (1) The present invention can precipitate zinc oxide crystals at designated locations by laying calcined zinc oxide particles on the surface of the body and combining them with specific surface glaze layer raw material components; and by controlling the particle size of the calcined zinc oxide particles to adjust the size of the crystals and simultaneously adjusting the distribution of the calcined zinc oxide, perfect crystals can be formed on the entire tile surface, thereby achieving a ceramic tile that not only feels like silk but also visually has the color and texture of silk, with a realistic imitation silk effect.

[0025] (2) The ceramic tiles of the present invention can achieve a silk-like glaze effect during preparation without changing the original preparation process of ordinary ceramic tiles, and are suitable for industrial applications. DETAILED DESCRIPTION

[0026] The present invention is described in detail below with reference to the examples to facilitate understanding of the present invention by those skilled in the art. It is necessary to point out that the examples are only used to further illustrate the present invention and are not to be construed as limiting the scope of protection of the present invention. Non-essential improvements and adjustments made to the present invention by those skilled in the art based on the above-mentioned invention should still fall within the scope of protection of the present invention. At the same time, the raw materials mentioned below that are not described in detail are all commercially available products; the process steps or preparation methods that are not mentioned in detail are all process steps or preparation methods known to those skilled in the art.

[0027] The green body raw materials used in the following examples and comparative examples are all powders of common commercially available glazed tiles.

[0028] The chemical composition of the transparent glaze used in the following examples and comparative examples is, by weight percentage, SiO2 48.5%, Al2O3 17%, ZnO 3%, ZrO2 1.5%, K2O 13%, TiO2 5%, MgO 3%, Na2O 5%, and B2O 34%.

[0029] Example 1

[0030] A ceramic tile comprises, from bottom to top, a body, a top glaze layer, and a transparent glaze layer. Zinc oxide flower crystals are distributed between the body and the top glaze layer. The zinc oxide flower crystals are precipitated during the firing process from calcined zinc oxide particles laid on the upper surface of the body. The calcined zinc oxide particles have an average particle size of 0.2 mm.

[0031] The thickness of the top glaze layer is 0.6mm, and the thickness of the clear glaze layer is 0.1mm.

[0032] The raw material components of the surface glaze layer include, by weight percentage, SiO2 50%, Al2O3 7%, ZnO 22%, K2O10%, MgO 3%, Na2O 1%, B2O3 3%, Fe2O3 0.2%, TiO2 0.3%, and colorant CuO 3.5%.

[0033] The clear glaze layer is fired from a matte clear glaze.

[0034] A method for preparing a ceramic tile comprises the following steps:

[0035] (1) First, a layer of powder for preparing a green body is laid in a mold, and then calcined zinc oxide particles are laid, and pressed into shape to obtain a green body with calcined zinc oxide laid on the surface;

[0036] (2) applying a top glaze and a transparent glaze in sequence to the upper surface of the green body obtained in step (1) to form a top glaze layer and a transparent glaze layer, and after firing, performing a soft polishing process to obtain the ceramic tile with the imitation silky glaze effect of this embodiment;

[0037] The firing temperature system is as follows: first heat up to 1200℃, keep warm for 50min; then cool down to 1100℃, keep warm for 120min; finally cool down to room temperature.

[0038] Example 2

[0039] A ceramic tile comprises, from bottom to top, a body, a top glaze layer, and a transparent glaze layer. Zinc oxide flower crystals are distributed between the body and the top glaze layer. The zinc oxide flower crystals are precipitated during the firing process from calcined zinc oxide particles laid on the upper surface of the body. The calcined zinc oxide particles have an average particle size of 0.3 mm.

[0040] The thickness of the top glaze layer is 0.8mm, and the thickness of the clear glaze layer is 0.1mm.

[0041] The raw material components of the glaze layer include, by weight percentage, SiO2 48.5%, Al2O3 7%, ZnO 23%, K2O7%, MgO 3%, Na2O 3%, B2O3 4%, Fe2O3 0.2%, TiO2 0.3%, and colorant CoO 4%.

[0042] The clear glaze layer is fired from a matte clear glaze.

[0043] A method for preparing a ceramic tile comprises the following steps:

[0044] (1) First, a layer of powder for preparing a green body is laid in a mold, and then calcined zinc oxide particles are laid, and pressed into shape to obtain a green body with calcined zinc oxide laid on the surface;

[0045] (2) applying a top glaze and a transparent glaze in sequence to the upper surface of the green body obtained in step (1) to form a top glaze layer and a transparent glaze layer, and after firing, performing a soft polishing process to obtain the ceramic tile with the imitation silky glaze effect of this embodiment;

[0046] The firing temperature system is as follows: first heat up to 1210°C and keep warm for 50 minutes; then cool down to 1120°C and keep warm for 120 minutes; finally cool down to room temperature.

[0047] Example 3

[0048] A ceramic tile comprises, from bottom to top, a body, a top glaze layer, and a transparent glaze layer. Zinc oxide flower crystals are distributed between the body and the top glaze layer. The zinc oxide flower crystals are precipitated during the firing process from calcined zinc oxide particles laid on the upper surface of the body. The calcined zinc oxide particles have an average particle size of 0.4 mm.

[0049] The thickness of the top glaze layer is 1 mm, and the thickness of the clear glaze layer is 0.1 mm.

[0050] The raw material components of the surface glaze layer include, by weight percentage, SiO2 45%, Al2O3 8%, ZnO 25%, K2O10%, MgO 4%, Na2O 1%, B2O3 3%, Fe2O3 0.2%, TiO2 0.3%, and colorant V2O5 3.5%.

[0051] The clear glaze layer is fired from a matte clear glaze.

[0052] A method for preparing a ceramic tile comprises the following steps:

[0053] (1) First, a layer of powder for preparing a green body is laid in a mold, and then calcined zinc oxide particles are laid, and pressed into shape to obtain a green body with calcined zinc oxide laid on the surface;

[0054] (2) applying a top glaze and a transparent glaze in sequence to the upper surface of the green body obtained in step (1) to form a top glaze layer and a transparent glaze layer, and after firing, performing a soft polishing process to obtain the ceramic tile with the imitation silky glaze effect of this embodiment;

[0055] The firing temperature system is as follows: first heat up to 1220℃, keep warm for 60min; then cool down to 1150℃, keep warm for 120min; finally cool down to room temperature.

[0056] Comparative Example 1

[0057] A ceramic tile comprises, from bottom to top, a body, a surface glaze layer and a transparent glaze layer.

[0058] The thickness of the top glaze layer is 0.6mm, and the thickness of the clear glaze layer is 0.1mm.

[0059] The raw material components of the surface glaze layer include, by weight percentage, SiO2 50%, Al2O3 7%, ZnO 22%, K2O10%, MgO 3%, Na2O 1%, B2O3 3%, Fe2O3 0.2%, TiO2 0.3%, and colorant CuO 3.5%.

[0060] The clear glaze layer is fired from a matte clear glaze.

[0061] A method for preparing a ceramic tile comprises the following steps:

[0062] (1) preparing powder for the green body in a mold and pressing it into shape to obtain the green body;

[0063] (2) applying a top glaze and a transparent glaze in sequence to the upper surface of the green body obtained in step (1) to form a top glaze layer and a transparent glaze layer, and after firing, performing a soft polishing process to obtain the ceramic tile of this comparative example;

[0064] The firing temperature system is as follows: first heat up to 1200℃, keep warm for 50min; then cool down to 1100℃, keep warm for 120min; finally cool down to room temperature.

[0065] The only difference between Comparative Example 1 and Example 1 is that the ceramic tile of Comparative Example 1 does not have zinc oxide particles laid on the upper surface of the green body.

[0066] Comparative Example 2

[0067] The only difference between Comparative Example 2 and Example 1 is that the thickness of the glaze layer of the ceramic tile in Comparative Example 2 is 0.2 mm, and the types and addition amounts of other raw materials and the preparation method of the ceramic tile are the same as those in Example 1.

[0068] Comparative Example 3

[0069] The only difference between Comparative Example 3 and Example 1 is that the average particle size of the calcined zinc oxide in the ceramic tiles of Comparative Example 3 is 0.05 mm, and the types and addition amounts of other raw materials and the preparation method of the ceramic tiles are the same as those in Example 1.

[0070] Comparative Example 4

[0071] The only difference between Comparative Example 4 and Example 1 is that the firing system of the ceramic tiles in Comparative Example 4 is: directly heating to 1200°C, keeping warm for 50 minutes, and then cooling to room temperature without cooling and keeping warm in the cooling stage; the raw materials and addition amounts of the ceramic tiles are the same as those in Example 1.

[0072] Comparative Example 5

[0073] The only difference between Comparative Example 5 and Example 1 is that the glaze used for the ceramic tiles in Comparative Example 5 is a commercially available ordinary glaze, and its chemical composition, by weight percentage, includes: SiO2 58.80%, Al2O3 29.28%, Fe2O3 0.2%, TiO20.01%, CaO 0.77%, MgO 0.13%, K2O 1.48%, Na2O 3.56%, ZrO2 0.56%, ZnO1.35%, IL 3.86%. The types and addition amounts of other raw materials and the preparation method of the ceramic tiles are the same as those in Example 1.

[0074] Performance Testing

[0075] The ceramic tile samples obtained in Examples 1-3 and Comparative Examples 1-5 were subjected to relevant performance tests, wherein the surface decoration effect was visually inspected. The test results are shown in Table 1 below.

[0076] Table 1 Performance test comparison table of each embodiment and comparative example

[0077] sample Gloss (°) Crystal size (cm) glaze effect Example 1 13 5-7 The pattern covers the entire surface of the brick, giving it a silk glaze effect Example 2 14 6-8 The pattern covers the entire surface of the brick, giving it a silk glaze effect Example 3 16 8-10 The pattern covers the entire brick surface, with a silk glaze effect Comparative Example 1 13 Crystalless Flower No silk glaze effect Comparative Example 2 8 1-2 Incomplete crystal form and rough glaze Comparative Example 3 13 1-2 The crystals are too small to fill the glaze and do not have a silk effect. Comparative Example 4 13 Crystalless Flower No silk glaze effect Comparative Example 5 13 Crystalless Flower No silk glaze effect

[0078] As can be seen from Table 1, the glossiness of the ceramic tiles prepared in Examples 1-3 is 13-16°, with a natural luster, a crystal size of 5-10 cm, and the pattern covers the entire tile surface, making the product not only similar to silk in touch, but also visually having the color and texture of silk, with a realistic imitation silk effect.

[0079] Compared with Example 1, the ceramic tile samples of Comparative Examples 1 and 4-5 are unable to precipitate zinc oxide crystals in the products because calcined zinc oxide particles are not laid on the green body during preparation, insulation is not performed during the cooling stage, and ordinary commercial glaze is used. As a result, the products only feel like silk, but visually do not have the color and texture of silk.

[0080] Compared with Example 1, the ceramic tile sample of Comparative Example 2 has an incomplete zinc oxide crystal structure due to the thin thickness of the surface glaze layer, and the glaze surface is rough and the glossiness is reduced. It is impossible to obtain a silky touch and there is no silky color and texture.

[0081] Compared with Example 1, the ceramic tile sample of Comparative Example 3 has a smaller average particle size of the calcined zinc oxide laid on the body during preparation, so the precipitated zinc oxide crystals are too small and cannot fill the glaze surface, which also results in the product being unable to achieve a good silk-like effect.

[0082] For those skilled in the art to which the present invention belongs, a number of simple deductions or substitutions can be made without departing from the concept of the present invention, without having to resort to creative work. Therefore, based on the disclosure of the present invention, simple improvements made by those skilled in the art to the present invention should be within the scope of protection of the present invention. The above embodiments are preferred embodiments of the present invention, and all processes similar to the present invention and equivalent changes made should fall within the scope of protection of the present invention.

Claims

1. A ceramic tile, characterized in that: From bottom to top, the composition includes a body, a top glaze layer, and a transparent glaze layer; zinc oxide crystals are distributed between the body and the top glaze layer, and the zinc oxide crystals are precipitated from calcined zinc oxide particles laid on the upper surface of the body during the firing process, and the average particle size of the calcined zinc oxide particles is 0.2-0.4 mm; the raw material components of the top glaze layer include, by weight percentage, SiO2 45-50%, Al2O3 5-10%, ZnO 20-25%, K2O 5-10%, MgO3-5%, Na2O 1-3%, B2O3 3-5%, Fe2O3 0.1-0.5%, and TiO2 0.2-0.4%; the thickness of the top glaze layer is 0.5-1 mm; The firing temperature system of the ceramic tiles is: firstly heating to 1200-1220°C and keeping the temperature for 30-60 minutes; then cooling to 1100-1150°C and keeping the temperature for 100-140 minutes; and finally cooling to room temperature.

2. The ceramic tile according to claim 1, characterized in that The transparent glaze layer is formed by firing a matte transparent glaze, and the glossiness of the matte transparent glaze is 12-16°.

3. The ceramic tile according to claim 1, characterized in that The raw material components of the surface glaze layer also include 3-5 wt% of a colorant.

4. The ceramic tile according to claim 3, characterized in that The colorant is selected from at least one of CuO, V2O5, CoO, and Ni2O3.

5. A method for preparing a ceramic tile according to any one of claims 1 to 4, characterized in that: The following steps are involved: (1) First, a layer of powder for preparing a green body is laid in a mold, and then calcined zinc oxide particles are laid, and pressed into shape to obtain a green body with calcined zinc oxide laid on the surface; (2) applying a top glaze and a transparent glaze in sequence on the upper surface of the green body to form a top glaze layer and a transparent glaze layer, and firing the glaze to obtain the ceramic tile; The sintering temperature system is as follows: firstly heating to 1200-1220° C. and keeping the temperature for 30-60 minutes; then cooling to 1100-1150° C. and keeping the temperature for 100-140 minutes; and finally cooling to room temperature.

6. The preparation method according to claim 5, characterized in that In step (2), after firing, the transparent glaze layer is also soft-polished.

7. The preparation method according to claim 5, characterized in that In step (2), the sintering atmosphere is an oxidizing atmosphere.