Ceramic tile with three-dimensional silk-like dyeing effect and preparation method thereof

Abstract

The present invention discloses a ceramic tile with a three-dimensional silk-like dyeing effect and a preparation method thereof, and relates to the technical field of ceramic tiles. The preparation method of the present invention is as follows: applying a reducing glaze at a preset position on the surface of a brick blank to obtain a reducing glaze layer; the raw materials of the reducing glaze include 59-81 parts of flux, 24-30 parts of boron frit, 5-10 parts of kaolin, and 0.2-0.8 parts of silicon carbide, and the raw materials of the boron frit include 17-23 parts of borax; inkjet printing is performed on the surface of the reducing glaze layer to obtain an inkjet layer; applying a transparent polishing glaze on the surface of the inkjet layer to obtain a polishing glaze layer; firing in a kiln to obtain a ceramic tile; the fluidity of the reducing glaze during firing is greater than the fluidity of the transparent polishing glaze during firing. The preparation method of the present invention can produce ceramic tiles with a three-dimensional silk-like dyeing effect, and the ceramic tile surface has distinct layered flow lines, obvious color levels, and various changes. The ceramic tile effect is unique, which solves the problems of the existing ceramic tile surface having insufficient color richness, unclear layered colors, and lack of three-dimensional sense.

Description

Technical Field

[0001] The present invention relates to the technical field of ceramic tiles, and in particular to a ceramic tile with a three-dimensional filamentous dyeing effect and a preparation method thereof. Background Art

[0002] To enhance the decorative effect of ceramic tiles, a decorative layer is often added to the base glaze during tile production. With the development of inkjet printing technology, most ceramic industries now use it to decorate tile surfaces, creating a decorative layer. This technology allows for high-definition, lifelike patterns on the tile surface, and allows for instant change of patterns, enabling personalized customization.

[0003] The method of using inkjet printing technology to form colorful patterns on the surface of ceramic tiles is as follows: ink containing colored metal ions is sprayed from a nozzle with a diameter of tens of microns, and is rapidly deposited on the surface of the brick at a speed of thousands of drops per second. After high-temperature firing, a color decorative effect is presented on the surface of the brick.

[0004] Although inkjet printing technology can form high-definition and realistic patterns on the surface of ceramic tiles, the use of inkjet printing technology to create decorative effects on ceramic tiles still has the following disadvantages: since the colored metal materials used in the inkjet layer usually show different colors in the oxidized state and the reduced state, and the current conventional ceramic tile sintering process is usually carried out in an oxidizing atmosphere, the colored metal materials in the inkjet layer can usually only show the color of the oxidized state, so that the color changes of the patterns on the surface of the resulting ceramic tile products are relatively simple and the colors are not rich enough; and when the decorative effect is produced by simulating related pictures through inkjet printing, the obtained pattern layers are not bright in color and can usually only simulate flat layers, lacking a sense of three-dimensionality and appearing dull. Summary of the Invention

[0005] In view of the above-mentioned deficiencies in the prior art, the purpose of the present invention is to propose a method for preparing ceramic tiles with a three-dimensional silk-like dyeing effect, which can produce ceramic tiles with a three-dimensional silk-like dyeing effect in part, and the surface of the ceramic tiles has distinct layered flow patterns, obvious color levels, and various changes, making the ceramic tiles unique, and solving the problems of the existing ceramic tile surfaces having single colors, unclear layered colors, and lack of three-dimensional sense.

[0006] Another object of the present invention is to provide a ceramic tile with a three-dimensional silk-like dyeing effect. The ceramic tile prepared by the above-mentioned preparation method has a three-dimensional silk-like dyeing effect on the surface, and has rich colors, distinct layers, and a unique decorative effect.

[0007] To achieve this object, the present invention adopts the following technical solutions:

[0008] A method for preparing a ceramic tile with a three-dimensional filamentous dyeing effect comprises the following steps:

[0009] (1) applying a reducing glaze at a preset position on the surface of the brick to obtain a reducing glaze layer; wherein, calculated by weight, the raw materials of the reducing glaze include 59-81 parts of flux, 24-30 parts of boron frit, 5-10 parts of kaolin and 0.2-0.8 parts of silicon carbide, and the raw materials of the boron frit include 17-23 parts of borax;

[0010] (2) performing inkjet printing on the surface of the reduced glaze layer to obtain an inkjet layer; wherein the raw material of the ink used in the inkjet printing step includes a colored metal material;

[0011] (3) applying a transparent glaze on the surface of the inkjet layer to obtain a glaze layer;

[0012] (4) placing the bricks coated with transparent glaze in step (3) into a kiln for firing to obtain ceramic tiles having a three-dimensional silk-like dyeing effect;

[0013] The fluidity of the reducing glaze during firing is greater than the fluidity of the transparent polishing glaze during firing.

[0014] Preferably, the melting temperature of the reducing glaze is 1100-1150°C, and the melting temperature of the transparent polishing glaze is 1140-1200°C.

[0015] Preferably, the mesh size of the silicon carbide is greater than 600 meshes.

[0016] Preferably, calculated by mass, the raw materials of the boron frit include 17-23 parts of borax, 17-27 parts of albite, 10-16 parts of potassium feldspar, 10-24 parts of wollastonite, 15-21 parts of quartz and 6-14 parts of kaolin.

[0017] Preferably, in step (1), the flux comprises albite, calcined talc, barium carbonate and potassium feldspar, and the raw materials of the reduction glaze comprise, by weight, 27 to 37 parts of albite, 1 to 5 parts of calcined talc, 1 to 3 parts of barium carbonate, 20 to 36 parts of potassium feldspar, 24 to 30 parts of boron frit, 5 to 10 parts of kaolin and 0.2 to 0.8 parts of silicon carbide.

[0018] Preferably, in step (1), the reducing glaze is applied to a preset position on the surface of the brick by screen printing.

[0019] Preferably, in step (2), the colored metal material includes any one or more combinations of copper oxide, iron oxide, cobalt oxide and chromium oxide.

[0020] Preferably, the glazing thickness of the reducing glaze layer is 0.02 mm to 0.15 mm, the inkjet thickness of the inkjet layer is 8 to 12 μm, and the glazing thickness of the polishing glaze layer is 0.3 mm to 0.8 mm.

[0021] Preferably, the method further comprises the steps of preparing a boron frit, comprising:

[0022] Mix the raw materials of the boron frit according to the proportion;

[0023] firing the mixed material;

[0024] After firing, the product is quenched in water to obtain a boron frit;

[0025] Wherein, the melting temperature curve of the boron frit includes:

[0026] It takes 80 to 120 minutes to heat up from room temperature to 1100°C.

[0027] Heating from 1100°C to 1430°C takes 35 to 60 minutes;

[0028] Keep at 1430℃ for 5~20min.

[0029] A ceramic tile with a three-dimensional silk-like dyeing effect is prepared by the above-mentioned method for preparing a ceramic tile with a three-dimensional silk-like dyeing effect, and comprises, from bottom to top, a brick blank, a reduction glaze layer, an inkjet layer and a polished glaze layer.

[0030] The technical solution provided by the embodiment of the present application may include the following beneficial effects: the technical solution adds a reducing glaze layer below the inkjet layer, and the raw materials of the reducing glaze include 59-81 parts of flux, 24-30 parts of boron frit, 5-10 parts of kaolin and 0.2-0.8 parts of silicon carbide. By changing the structure of the ceramic tiles and adopting a specially formulated reducing glaze, after sintering, a three-dimensional dyeing and immersion decorative effect and a flow effect will be produced on the surface of the ceramic tiles, and the layers are distinct, the color layers are obvious, the changes are diverse, and the decorative effect is unique, which solves the problems of the existing ceramic tile surfaces having single colors, unclear layered colors and lack of three-dimensional sense. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 This is a rendering of a ceramic tile with a three-dimensional silky dyeing effect produced in Example 1 of the present invention. DETAILED DESCRIPTION

[0032] For ease of understanding of the present invention, the present invention will be described more fully below. The present invention can be implemented in many different forms and is not limited to the embodiments described herein. On the contrary, the purpose of providing these embodiments is to make the understanding of the disclosure of the present invention more thorough and comprehensive.

[0033] If no specific techniques or conditions are specified in the examples, the techniques or conditions described in the literature in this field or the product instructions were used. Raw materials used without manufacturer specified are all commercially available conventional products.

[0034] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the art to which this invention pertains. The terms used herein in the specification of the present invention are for the purpose of describing specific embodiments only and are not intended to limit the present invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0035] The technical solution of the present invention is further described below in conjunction with specific embodiments.

[0036] A method for preparing a ceramic tile with a three-dimensional filamentous dyeing effect comprises the following steps:

[0037] (1) applying a reducing glaze at a preset position on the surface of the brick to obtain a reducing glaze layer; wherein, calculated by weight, the raw materials of the reducing glaze include 59-81 parts of flux, 24-30 parts of boron frit, 5-10 parts of kaolin and 0.2-0.8 parts of silicon carbide, and the raw materials of the boron frit include 17-23 parts of borax;

[0038] (2) performing inkjet printing on the surface of the reduced glaze layer to obtain an inkjet layer; wherein the raw material of the ink used in the inkjet printing step includes a colored metal material;

[0039] (3) applying a transparent glaze on the surface of the inkjet layer to obtain a glaze layer;

[0040] (4) placing the bricks coated with transparent glaze in step (3) into a kiln for firing to obtain ceramic tiles having a three-dimensional silk-like dyeing effect;

[0041] The fluidity of the reducing glaze during firing is greater than the fluidity of the transparent polishing glaze during firing.

[0042] This technical solution adds a reducing glaze layer below the inkjet layer. The raw materials of the reducing glaze include 59-81 parts of flux, 24-30 parts of boron frit, 5-10 parts of kaolin and 0.2-0.8 parts of silicon carbide. Through the change of the tile structure and the use of a specially formulated reducing glaze, after sintering, a three-dimensional dyeing and immersion decorative effect and a flow effect will be produced on the tile surface. The layers are distinct, the colors are obvious, the changes are diverse, and the decorative effect is unique, which solves the problems of the existing tile surface with single color patterns, unclear layer colors and lack of three-dimensional sense.

[0043] It is worth noting that this technical solution provides a reducing glaze layer below the inkjet layer. The inkjet layer contains colored metal materials, and the inkjet layer is colored by the colored metal materials. Since the reducing glaze layer is located below the inkjet layer, and the reducing glaze is applied to a preset position on the surface of the brick, and since the reducing glaze has a certain thickness, the inkjet layer attached to the surface of the reducing glaze layer will also have certain undulations relative to the surface of the brick.

[0044] Since the reducing glaze of the present technical solution is applied to the preset position on the surface of the brick, that is, some positions of the formed reducing glaze layer will be applied with reducing glaze, while some positions will not be applied with reducing glaze, the positions where the reducing glaze is applied in the reducing glaze layer are named as glazed protrusions, and the positions where the reducing glaze is not applied are named as recessed portions; based on the introduction of 0.2-0.8 parts of silicon carbide (SiC) into the reducing glaze formula, SiC will oxidize and decompose to release CO under the high temperature of the sintering process, and CO can partially or completely take away the oxygen element of the colored metal material above the glazed protrusion, so that the colored metal material above the glazed protrusion is The colored metal ions in the glazed part are reduced to low-valent atoms. Due to the different valence states of the colored metal ions, their colors are also different, so that the colored metal material above the glazed raised part is the color of the reduced state, and since the depressed part is not coated with reducing glaze, the colored metal material in the inkjet layer corresponding to the depressed part is not reduced and is the color of the oxidized state. Therefore, the color of the ink on the surface of the glazed raised part after firing is different from the color of the ink above the depressed part. Therefore, after sintering, the top layer of transparent glaze will present a three-dimensional layered effect and the color of the tile surface will change in various ways. Secondly, SiC will release a lot of CO gas due to oxidation decomposition at high temperature. The CO gas is discharged from the reducing glaze layer through the inkjet layer and the polishing glaze layer in turn, so that the high-temperature fluidity of the glaze at the gas discharge point is inconsistent with the surrounding area, and the CO gas will carry the reduced colored metal ions out of the polishing glaze layer during the discharge process, so that some of the reduced colored metal ions remain on the discharge path, thereby causing irregular and distinct layered flow patterns to appear on the glaze surface; moreover, the reducing glaze obtained by the formula configuration of this technical solution has good fluidity after high-temperature melting, while the transparent polishing glaze is a conventional transparent polishing glaze in this field, which has poor fluidity, resulting in a large flow difference between the reducing glaze and the transparent polishing glaze. During the firing process, the reducing glaze and the transparent polishing glaze will pull the inkjet layer in the middle, creating extremely natural halo colors and flow patterns. Therefore, the preparation method of this technical solution can make the prepared tiles produce three-dimensional dyeing and immersion decorative effects and flow patterns by changing the tile structure and using a specially formulated reducing glaze, and the decorative effect has distinct layers, obvious color layers, and various changes, and the decorative effect is unique, as shown in the attached Figure 1 shown.

[0045] Further explanation is that the coloring ions of the colored metal material in the inkjet layer are very sensitive to the atmosphere in the kiln during the firing process. SiC will release CO due to oxidation and decomposition at high temperature, and CO can remove part or all of the oxygen in the colored metal material to achieve a reducing atmosphere, so that the pattern color of the inkjet layer at the position corresponding to the reduced glaze is different from the pattern color of other positions of the inkjet layer, thereby presenting a colorful effect. However, this reaction is reversible. In order to prevent the reduced coloring ions from being oxidized again, this technical solution solves this problem through structural design, mainly covering a glaze layer on top of the inkjet layer. When the coloring ions are reduced, the outermost transparent glaze will form a transparent glass layer (i.e., the glaze layer), which can prevent the reduced coloring ions below the transparent glass layer from being oxidized again to the greatest extent.

[0046] This technical solution adds 24-30 parts of boron frit to the reduction glaze formula. Boron frit significantly reduces the firing temperature of the reduction glaze, increasing its fluidity during high-temperature firing. This allows the reduced colored metal material in the inkjet layer above the reduction glaze (different in color from the oxidized colored metal material surrounding the unreduced glaze) to flow with the glaze, creating rich rhytmic colors. Furthermore, the addition of 24-30 parts of boron frit and the use of 59-81 parts of flux to the reduction glaze formula significantly enhances its fluidity during high-temperature firing. This significantly reduces the fluidity difference between the reduction glaze and the clear polished glaze, making the reduction glaze far more fluid than the clear polished glaze. This allows the reduction glaze to flow at the interface between the reduction glaze layer and the inkjet layer, as well as at the interface between the inkjet layer and the polished glaze layer. Furthermore, since the inkjet layer is typically very thin, the significant fluidity difference between the reduction glaze and the clear polished glaze can create a cross-dyeing effect, resulting in a natural color flow. On the other hand, the decomposition temperature of silicon carbide is relatively high (around 2200°C). This technical solution significantly reduces the decomposition temperature of silicon carbide by adding boron frit to the reduction glaze formula. At the same time, the addition of a large amount of flux further reduces the decomposition temperature of silicon carbide, allowing silicon carbide to decompose at 1100°C to 1130°C. This ensures that the inkjet layer above the reduction glaze layer is self-reduced when silicon carbide decomposes in the high-temperature zone of firing. Secondly, because the reduction glaze is below the inkjet layer, the CO bubbles generated during its decomposition will move upward at high temperatures. When passing through the inkjet layer, they will carry the colored metal materials of the inkjet layer into the polished glaze layer until the bubbles are expelled from the polished glaze layer. However, the colored ions carried by the bubbles will remain in the polished glaze layer along the track of the expelled glaze layer, and the residue will remain in the polished glaze layer according to the track, thus producing a filamentous and three-dimensional decorative effect, further ensuring the distinct and varied color layers on the tile surface.

[0047] To further explain, during the high-temperature firing process, when the temperature is between 1100°C and 1130°C, a large amount of liquid phase has appeared in the reducing glaze, which will form a dense intermediate layer with the bottom of the inkjet layer and the polished glaze layer, sandwiching the inkjet layer in the middle, so that the inkjet layer cannot contact the upper part of the polished glaze layer where there is a gap. Even if the inkjet layer is basically not exposed to oxygen, it can prevent the inkjet layer from being oxidized again by the reduced colored metal materials. In the process of CO gas discharge, CO gas will pass through the intermediate layer, enter the upper part of the polished glaze layer, and then be discharged from the polished glaze layer. Since CO gas carries part of the reduced colored metal materials out of the dense intermediate layer and reaches the top of the polished glaze layer during the discharge process, this part of the reduced colored metal materials will come into contact with oxygen on the upper part of the polished glaze layer after leaving the dense intermediate layer, and will be oxidized again, making the color richer.

[0048] Further explanation: The boron frit addition in the reduction glaze of this technical solution is controlled at 24-30 parts. This ensures that the reduction glaze has high fluidity during high-temperature firing, thereby producing a clear flow pattern and color immersion effect. It also ensures that silicon carbide decomposes within the appropriate temperature range (1100°C-1130°C), thereby reducing the coloring ions and carrying them out. If the boron frit addition in the reduction glaze formula is too low, the fluidity of the reduction glaze will be too low, with little difference from the fluidity of the transparent polished glaze, resulting in less obvious flow pattern and color immersion effect. At the same time, if the boron frit addition is too low, the silicon carbide cannot be decomposed within the appropriate temperature range (1100°C-1130°C), failing to achieve the effect of reducing the coloring ions and carrying them out. If the boron frit addition in the reduction glaze formula is too high, the reduction glaze can easily overfire and boil, generating excessive bubbles, causing glaze defects. The silicon carbide content in the reduction glaze formulation of this technical solution is controlled at 0.2-0.8 parts. This ensures that the colored metal material in the inkjet layer corresponding to the reduced glaze design is reduced, resulting in a different color from the unreduced glaze design (because many colored metal materials exhibit different colors when oxidized and reduced), thus creating a rich color effect. If the silicon carbide content is less than 0.2 parts, the colored metal material in the inkjet layer will not be able to self-reduced properly, resulting in a monotonous color tone of the finished tile. If the silicon carbide content is greater than 0.8 parts, excessive bubbles will be generated during the decomposition of the silicon carbide, resulting in defects such as pinholes and bubbles in the glaze layer.

[0049] Specifically, in step (1) of the present technical solution, before applying the reducing glaze, it is also necessary to apply the base glaze on the surface of the brick. By applying the base glaze first, the base color of the brick can be covered, which is conducive to presenting a better color effect later.

[0050] It is worth noting that the decorative effect of the tiles produced by the present technical solution can not only be expressed as the above-mentioned dyeing and immersion, flow, inkjet layer undulation, silk-like three-dimensional and other effects, but can also be expressed in color. For example, a variety of colored metal materials can be added to the inkjet layer. These colored metal materials are self-reduced by silicon carbide above the reducing glaze, and show a different color from the colored metal materials in the oxidizing atmosphere of the area without reducing glaze, resulting in gorgeous colors; in addition, one or more colored metal materials can be introduced into both the inkjet layer and the reducing glaze layer, and the surface of the colored tiles obtained can be more colorful and more gorgeous. By superimposing multiple effects, the design pattern can be partially monochrome or multi-color shading and have a distinct decorative effect.

[0051] Further explanation: the melting temperature of the reducing glaze is 1100~1150℃, and the melting temperature of the transparent polishing glaze is 1140~1200℃.

[0052] It is worth noting that the present technical solution can significantly reduce the melting temperature of the reducing glaze by adding a large amount of boron frit and flux to the reducing glaze, so that the reducing glaze can reach initial melting at around 1100°C, with the liquid phase appearing and silicon carbide decomposing. At the same time, due to the presence of a large amount of boron frit and flux in the formula system, the reducing glaze has a low high-temperature viscosity and good fluidity. The transparent polishing glaze used in this application is a commonly used polishing glaze in the field. In order to avoid over-firing or under-firing of the transparent polishing glaze, it is usually required that the firing temperature of the transparent polishing glaze matches the firing temperature of the brick blank, and the firing temperature (i.e., melting temperature) of the transparent polishing glaze and the firing temperature of the brick blank are required to be within a relatively close range. Therefore, the melting temperature range of the transparent polishing glaze used in this solution is 1140~1200°C, and the melting temperature of the transparent polishing glaze is greater than the melting temperature of the reducing glaze. At the same time, the high-temperature viscosity of the transparent polishing glaze of this solution is much greater than that of the reducing glaze, resulting in a significant difference in melting temperature and high-temperature viscosity between the reducing glaze and the transparent polishing glaze. Due to the difference in melting temperature and high-temperature fluidity between reducing glaze and transparent polishing glaze, and the inconsistency between the color of the inkjet layer in the area corresponding to the reducing glaze and the area without reducing glaze, the extremely thin inkjet layer in the middle will be pulled between the two layers of glaze, forming a very natural mutual dyeing and immersion effect, further enriching the color effect of the tiles.

[0053] To further explain, the melting temperature range of the reducing glaze in the present technical solution is 1100~1150℃, and the decomposition temperature of silicon carbide in the reducing glaze is controlled at 1100℃~1130℃. Therefore, in the temperature range of 1100~1150℃, the reducing glaze in the present technical solution is basically completely melted, and a large amount of liquid phase appears. However, the amount of liquid phase appearing in the polishing layer in this temperature range is not large, and it is not able to completely fill the gaps between the particles, so that there are some gaps in the polishing layer. When the CO gas encounters liquid phase obstruction when being discharged upward, it will be discharged from the gaps between other particles, and the colored metal material carried in the gaps between the particles will be immediately oxidized by the oxygen in the gaps, and will appear filamentous against the background of the reduced colored metal material in the lower layer of ink. Therefore, the present solution can produce a filamentous and three-dimensional decorative effect.

[0054] Specifically, the transparent glaze used in this application is a glaze commonly used in this field. Preferably, the transparent glaze includes the following raw materials in parts by mass: 30-44 parts of potassium feldspar, 13-19 parts of wollastonite, 5-15 parts of dolomite, 1-3 parts of calcined talc, 4-8 parts of zinc oxide, 4-6 parts of barium carbonate, 4-6 parts of barium sulfate, 10-14 parts of quartz, 4-6 parts of kaolin and 1-3 parts of white corundum. The flux in the transparent glaze formula of this technical solution is mainly potassium feldspar and divalent minerals. The temperature at which the liquid phase appears is 40-50°C higher than that of sodium feldspar and boron frit in the reduction glaze. Therefore, the melting temperature of this transparent glaze is 1140-1200°C.

[0055] Further explanation: the mesh size of the silicon carbide is above 600 mesh.

[0056] It is worth noting that the silicon carbide used in the reduction glaze formula of this technical solution needs to be processed to above 600 mesh first. By reducing the fineness of silicon carbide, the surface area of ​​contact between silicon carbide particles and the glaze melt can be increased, thereby achieving the effect of lowering the decomposition temperature of silicon carbide; and when the decomposition temperature of silicon carbide is low, the temperature when discharging CO gas is earlier, so that the CO gas has enough time to be discharged from the glaze layer, thereby preventing the occurrence of bubbles or glaze bubbles and other defects in the glaze layer. At the same time, based on the small size of silicon carbide particles, the entire decomposition process of silicon carbide will be shortened, creating more time for the glaze layer to discharge bubbles. Moreover, since the silicon carbide particles are small, the silicon carbide will be more evenly distributed and more widely distributed in the reduction glaze layer, making it less likely for bubbles to agglomerate together, and the bubble discharge channel will be smoother, thereby effectively preventing defects such as glaze bubbles.

[0057] Further explanation, calculated by mass, the raw materials of the boron frit include 17-23 parts of borax, 17-27 parts of albite, 10-16 parts of potassium feldspar, 10-24 parts of wollastonite, 15-21 parts of quartz and 6-14 parts of kaolin.

[0058] The boron frit of the present invention contains 17-23 parts of borax and a relatively large amount of flux, such as potassium feldspar, sodium feldspar, and wollastonite. The melting temperature of borax is relatively low, at around 880°C, and borax also forms a low eutectic point with other fluxes, which lowers the temperature at which the boron frit appears in the liquid phase. This results in a larger amount of liquid phase in the boron frit at lower temperatures, which wraps the silicon carbide in the liquid phase, thereby accelerating the decomposition of the silicon carbide. Since the reduction glaze of the present invention contains 24-30 parts of low-temperature, highly fluxing boron frit and 59-81 parts of flux, the reduction glaze has a large amount of liquid phase during high-temperature firing. Due to its low melting temperature, the viscosity of the reduction glaze decreases as the firing temperature increases. When the sintering temperature of the clear polished glaze is reached, the viscosity of the reduction glaze is much lower than that of the clear polished glaze, resulting in a large melting temperature difference and high-temperature viscosity difference between the reduction glaze and the clear polished glaze, which creates a very natural inter-dyed and immersion-colored shading effect on the glaze surface.

[0059] Specifically, the quartz and kaolin in the boron frit are high-temperature materials. Adding a certain amount of quartz and kaolin can prevent the boron frit from being overfired before reaching the sintering temperature of the reduction glaze.

[0060] Further explanation, in step (1), the flux includes albite, calcined talc, barium carbonate and potassium feldspar, and calculated by mass, the raw materials of the reduction glaze include 27-37 parts of albite, 1-5 parts of calcined talc, 1-3 parts of barium carbonate, 20-36 parts of potassium feldspar, 24-30 parts of boron frit, 5-10 parts of kaolin and 0.2-0.8 parts of silicon carbide.

[0061] The fluxes in the reduction glaze of the present technical solution include albite, burned talc, barium carbonate and potassium feldspar. These fluxes, combined with boron frit, can have a strong fluxing effect, so that the reduction glaze can produce a large amount of liquid phase to encapsulate silicon carbide at a temperature of 1100~1150℃, causing the silicon carbide to decompose.

[0062] To further illustrate, in step (1), the reducing glaze is applied to a preset position on the surface of the brick by screen printing.

[0063] The present technical solution uses screen printing to apply reducing glaze on a preset position on the surface of the brick. First, the screen can be designed into different patterns, and it can be determined which positions are to be printed with reducing glaze and which positions do not need to be printed with reducing glaze, so that there are undulations at the junction of the positions where reducing glaze is applied and the positions where reducing glaze is not applied, so that the surface of the produced ceramic tile presents a three-dimensional sense of layering. Secondly, the screen can be designed with a variety of different mesh counts. Due to the different mesh counts of the screen, the thickness of the applied reducing glaze will be inconsistent, thus forming undulations; furthermore, screen printing can be stacked, that is, the design pattern is crossed to form undulations with a more three-dimensional sense of layering. Moreover, the present technical solution uses screen printing to apply reducing glaze on the surface of the brick. Since screen printing is a common and mature process in the field of ceramic production, the design of the pattern, thickness and process of applying the reducing glaze are controllable.

[0064] To further illustrate, in step (2), the colored metal material includes any one or more combinations of copper oxide, iron oxide, cobalt oxide and chromium oxide.

[0065] It is worth noting that the colored metal material used in the present technical solution is a colored metal material, and any colored metal material commonly used in the art can be selected. For example, in a preferred embodiment of the present technical solution, the colored metal material can be selected from any one or more combinations of copper oxide, iron oxide, cobalt oxide and chromium oxide. These colored metal materials will show different colors in the oxidized state and the reduced state. Since ceramic tile firing is usually carried out in an oxidizing atmosphere, the colored metal material in the inkjet layer usually exists in the form of oxides. The present technical solution applies a reducing glaze under the inkjet layer, and the reducing glaze is applied to the surface of the brick according to a specific design pattern (the group required can be designed according to demand), that is, the reducing glaze is only applied to the specified position on the surface of the brick. The silicon carbide in the reducing glaze will decompose during the high-temperature firing process to produce reducing gas - CO. The generated CO gas can reduce the colored metal material on the surface of the reducing glaze into reduced low-valent atoms, making the colored metal material show different colors. Therefore, the color of the area on the tile surface with the design pattern applied with the reducing glaze will be different from the color of the area without the reducing glaze, thereby making the color of the produced ceramic tile more colorful and the decorative effect better.

[0066] Further description, the glaze thickness of the reduction glaze layer is 0.02mm~0.15mm, the inkjet thickness of the inkjet layer is 8~12μm, and the glaze thickness of the polishing glaze layer is 0.3mm~0.8mm.

[0067] During the firing process, due to the difference in firing temperature (i.e. melting temperature difference) and high-temperature viscosity between the reduction glaze and the transparent polishing glaze, an extremely thin inkjet layer is pulled between the two layers of glaze, forming a mutual infiltration effect, which makes the halo color appear on the surface of the tile richer in color.

[0068] Further description also includes the steps of preparing the boron frit, including:

[0069] Mix the raw materials of the boron frit according to the proportion;

[0070] firing the mixed material;

[0071] After firing, the product is quenched in water to obtain a boron frit;

[0072] Wherein, the melting temperature curve of the boron frit includes:

[0073] It takes 80 to 120 minutes to heat up from room temperature to 1100°C.

[0074] Heating from 1100°C to 1430°C takes 35 to 60 minutes;

[0075] Keep at 1430℃ for 5~20min.

[0076] A ceramic tile with a three-dimensional silk-like dyeing effect is prepared by the above-mentioned method for preparing a ceramic tile with a three-dimensional silk-like dyeing effect, and comprises, from bottom to top, a brick blank, a reduction glaze layer, an inkjet layer and a polished glaze layer.

[0077] It is worth mentioning that the preparation method of the present technical solution can produce ceramic tiles with three-dimensional silk-like dyeing and immersion effects, irregular and distinct layered flow colors, diverse changes and unique decorative effects.

[0078] The technical solution of the present invention is further described below with reference to specific embodiments.

[0079] Example 1

[0080] A method for preparing a ceramic tile with a three-dimensional filamentous dyeing effect comprises the following steps:

[0081] (1) Applying reducing glaze on the surface of the brick by screen printing, so that the designated position of the brick surface is coated with reducing glaze to obtain a reducing glaze layer; calculated by weight, the raw materials of the reducing glaze include 32 parts of albite, 2 parts of calcined talc, 2 parts of barium carbonate, 30 parts of potassium feldspar, 28 parts of boron frit, 7 parts of kaolin and 0.6 parts of silicon carbide; the mesh size of silicon carbide is 625 mesh; the raw materials of the boron frit include 20 parts of borax, 22 parts of albite, 14 parts of potassium feldspar, 18 parts of wollastonite, 17 parts of quartz and 10 parts of kaolin;

[0082] (2) performing inkjet printing on the surface of the reduced glaze layer to obtain an inkjet layer, wherein the ink used for the inkjet printing contains a colored metal material;

[0083] (3) applying a transparent polishing glaze on the surface of the inkjet layer to obtain a polishing glaze layer; the transparent polishing glaze comprises the following raw materials in parts by weight: 38 parts of potassium feldspar, 17 parts of wollastonite, 11 parts of dolomite, 2 parts of calcined talc, 5 parts of zinc oxide, 5 parts of barium carbonate, 6 parts of barium sulfate, 12 parts of quartz, 4 parts of kaolin and 2 parts of white corundum;

[0084] (4) The bricks coated with transparent glaze in step (3) are placed in a kiln and fired at a firing temperature of 1180° C. to obtain ceramic tiles with a three-dimensional silk-like dyeing effect.

[0085] Among them, the melting temperature range of reduction glaze is 1105~1136℃, that is, the initial melting temperature of reduction glaze is 1105℃ and the complete melting temperature is 1136℃; the melting temperature range of transparent polishing glaze is 1145~1180℃, that is, the initial melting temperature is 1145℃ and the complete melting temperature is 1180℃;

[0086] The preparation method of the boron frit in this embodiment is as follows: the raw materials of the boron frit are mixed according to a proportion, the mixed material is fired, and then quenched in water after firing to obtain the boron frit; wherein, the melting temperature curve of the boron frit includes: heating from room temperature to 1100°C, which takes 100 minutes; heating from 1100°C to 1430°C, which takes 45 minutes; and keeping at 1430°C for 10 minutes.

[0087] Specifically, attached Figure 1 The effect diagram of the ceramic tile with three-dimensional silk dyeing effect obtained in this embodiment is shown in the attached figure. Figure 1 It can be seen that the ceramic tile produced in this embodiment has a three-dimensional dyed and immersed color decorative effect and flow pattern, and has distinct layers, obvious color layers, various changes, and a unique decorative effect.

[0088] Example 2

[0089] The method for preparing a ceramic tile having a three-dimensional filamentous dyeing effect in this embodiment comprises the following steps:

[0090] (1) Applying reducing glaze on the surface of the brick by screen printing, so that the designated position of the brick surface is coated with reducing glaze to obtain a reducing glaze layer; calculated by weight, the raw materials of the reducing glaze include 35 parts of albite, 3 parts of calcined talc, 1 part of barium carbonate, 25 parts of potassium feldspar, 30 parts of boron frit, 5 parts of kaolin and 0.8 parts of silicon carbide; the mesh size of silicon carbide is 600 mesh; the raw materials of the boron frit include 23 parts of borax, 17 parts of albite, 13 parts of potassium feldspar, 20 parts of wollastonite, 21 parts of quartz and 6 parts of kaolin;

[0091] (2) performing inkjet printing on the surface of the reduced glaze layer to obtain an inkjet layer, wherein the ink used for the inkjet printing contains a colored metal material;

[0092] (3) applying a transparent polishing glaze on the surface of the inkjet layer to obtain a polishing glaze layer; the transparent polishing glaze comprises the following raw materials in parts by weight: 38 parts of potassium feldspar, 17 parts of wollastonite, 11 parts of dolomite, 2 parts of calcined talc, 5 parts of zinc oxide, 5 parts of barium carbonate, 6 parts of barium sulfate, 12 parts of quartz, 4 parts of kaolin and 2 parts of white corundum;

[0093] (4) The bricks coated with transparent glaze in step (3) are placed in a kiln and fired at a firing temperature of 1180° C. to obtain ceramic tiles with a three-dimensional silk-like dyeing effect.

[0094] Among them, the melting temperature range of reduction glaze is 1110~1132℃; the melting temperature range of transparent polishing glaze is 1145~1180℃.

[0095] The preparation method of the boron frit in this embodiment is as follows: the raw materials of the boron frit are mixed according to a proportion, the mixed material is fired, and then quenched in water after firing to obtain the boron frit; wherein, the melting temperature curve of the boron frit includes: heating from room temperature to 1100°C, which takes 100 minutes; heating from 1100°C to 1430°C, which takes 45 minutes; and keeping at 1430°C for 10 minutes.

[0096] Example 3

[0097] The method for preparing a ceramic tile having a three-dimensional filamentous dyeing effect in this embodiment comprises the following steps:

[0098] (1) Applying reducing glaze on the surface of the brick by screen printing, so that the designated position of the brick surface is coated with reducing glaze to obtain a reducing glaze layer; calculated by weight, the raw materials of the reducing glaze include 27 parts of albite, 1 part of calcined talc, 3 parts of barium carbonate, 36 parts of potassium feldspar, 27 parts of boron frit, 6 parts of kaolin and 0.2 parts of silicon carbide; the mesh size of silicon carbide is 650 mesh; the raw materials of the boron frit include 18 parts of borax, 20 parts of albite, 12 parts of potassium feldspar, 24 parts of wollastonite, 15 parts of quartz and 14 parts of kaolin;

[0099] (2) performing inkjet printing on the surface of the reduced glaze layer to obtain an inkjet layer, wherein the ink used for the inkjet printing contains a colored metal material;

[0100] (3) applying a transparent polishing glaze on the surface of the inkjet layer to obtain a polishing glaze layer; the transparent polishing glaze comprises the following raw materials in parts by weight: 38 parts of potassium feldspar, 17 parts of wollastonite, 11 parts of dolomite, 2 parts of calcined talc, 5 parts of zinc oxide, 5 parts of barium carbonate, 6 parts of barium sulfate, 12 parts of quartz, 4 parts of kaolin and 2 parts of white corundum;

[0101] (4) The bricks coated with transparent glaze in step (3) are placed in a kiln and fired at a firing temperature of 1180° C. to obtain ceramic tiles with a three-dimensional silk-like dyeing effect.

[0102] Among them, the melting temperature range of reduction glaze is 1106~1140℃; the melting temperature range of transparent polishing glaze is 1145~1180℃.

[0103] The preparation method of the boron frit in this embodiment is as follows: the raw materials of the boron frit are mixed according to a proportion, the mixed material is fired, and then quenched in water after firing to obtain the boron frit; wherein, the melting temperature curve of the boron frit includes: heating from room temperature to 1100°C, which takes 100 minutes; heating from 1100°C to 1430°C, which takes 45 minutes; and keeping at 1430°C for 10 minutes.

[0104] Example 4

[0105] The method for preparing a ceramic tile having a three-dimensional filamentous dyeing effect in this embodiment comprises the following steps:

[0106] (1) Applying reducing glaze on the surface of the brick by screen printing, so that the designated position of the brick surface is coated with reducing glaze to obtain a reducing glaze layer; calculated by weight, the raw materials of the reducing glaze include 30 parts of albite, 4 parts of calcined talc, 2 parts of barium carbonate, 32 parts of potassium feldspar, 24 parts of boron frit, 8 parts of kaolin and 0.5 parts of silicon carbide; the mesh size of silicon carbide is 625 mesh; the raw materials of the boron frit include 17 parts of borax, 27 parts of albite, 10 parts of potassium feldspar, 22 parts of wollastonite, 17 parts of quartz and 12 parts of kaolin;

[0107] (2) performing inkjet printing on the surface of the reduced glaze layer to obtain an inkjet layer, wherein the ink used for the inkjet printing contains a colored metal material;

[0108] (3) applying a transparent polishing glaze on the surface of the inkjet layer to obtain a polishing glaze layer; the transparent polishing glaze comprises the following raw materials in parts by weight: 38 parts of potassium feldspar, 17 parts of wollastonite, 11 parts of dolomite, 2 parts of calcined talc, 5 parts of zinc oxide, 5 parts of barium carbonate, 6 parts of barium sulfate, 12 parts of quartz, 4 parts of kaolin and 2 parts of white corundum;

[0109] (4) The bricks coated with transparent glaze in step (3) are placed in a kiln and fired at a firing temperature of 1180° C. to obtain ceramic tiles with a three-dimensional silk-like dyeing effect.

[0110] Among them, the melting temperature range of reduction glaze is 1110~1148℃; the melting temperature range of transparent polishing glaze is 1145~1180℃.

[0111] The preparation method of the boron frit in this embodiment is as follows: the raw materials of the boron frit are mixed according to a proportion, the mixed material is fired, and then quenched in water after firing to obtain the boron frit; wherein, the melting temperature curve of the boron frit includes: heating from room temperature to 1100°C, which takes 100 minutes; heating from 1100°C to 1430°C, which takes 45 minutes; and keeping at 1430°C for 10 minutes.

[0112] Example 5

[0113] The method for preparing a ceramic tile having a three-dimensional filamentous dyeing effect in this embodiment comprises the following steps:

[0114] (1) Applying reducing glaze on the surface of the brick by screen printing, so that the designated position of the brick surface is coated with reducing glaze to obtain a reducing glaze layer; calculated by weight, the raw materials of the reducing glaze include 37 parts of albite, 5 parts of calcined talc, 2 parts of barium carbonate, 20 parts of potassium feldspar, 29 parts of boron frit, 10 parts of kaolin and 0.7 parts of silicon carbide; the mesh size of silicon carbide is 650 mesh; the raw materials of the boron frit include 22 parts of borax, 25 parts of albite, 16 parts of potassium feldspar, 10 parts of wollastonite, 19 parts of quartz and 8 parts of kaolin;

[0115] (2) performing inkjet printing on the surface of the reduced glaze layer to obtain an inkjet layer, wherein the ink used for the inkjet printing contains a colored metal material;

[0116] (3) applying a transparent polishing glaze on the surface of the inkjet layer to obtain a polishing glaze layer; the transparent polishing glaze comprises the following raw materials in parts by weight: 38 parts of potassium feldspar, 17 parts of wollastonite, 11 parts of dolomite, 2 parts of calcined talc, 5 parts of zinc oxide, 5 parts of barium carbonate, 6 parts of barium sulfate, 12 parts of quartz, 4 parts of kaolin and 2 parts of white corundum;

[0117] (4) The bricks coated with transparent glaze in step (3) are placed in a kiln and fired at a firing temperature of 1180° C. to obtain ceramic tiles with a three-dimensional silk-like dyeing effect.

[0118] Among them, the melting temperature range of reduction glaze is 1108~1143℃, that is, the initial melting temperature of reduction glaze is 1108, and the complete melting temperature is 1143℃; the melting temperature range of transparent polishing glaze is 1145~1180℃, that is, the initial melting temperature is 1145℃, and the complete melting temperature is 1180℃.

[0119] The preparation method of the boron frit in this embodiment is as follows: the raw materials of the boron frit are mixed according to a proportion, the mixed material is fired, and then quenched in water after firing to obtain the boron frit; wherein, the melting temperature curve of the boron frit includes: heating from room temperature to 1100°C, which takes 100 minutes; heating from 1100°C to 1430°C, which takes 45 minutes; and keeping at 1430°C for 10 minutes.

[0120] The technical principles of the present invention have been described above with reference to specific embodiments. These descriptions are intended solely to illustrate the principles of the present invention and are not to be construed in any way as limiting the scope of protection of the present invention. Based on the explanations herein, those skilled in the art will readily conceive of other specific embodiments of the present invention without inventive effort, and such embodiments will fall within the scope of protection of the present invention.

Claims

1. A method for preparing a ceramic tile with a three-dimensional silk-like dyeing effect, characterized in that: The following steps are involved: (1) applying a reducing glaze at a preset position on the surface of the brick to obtain a reducing glaze layer; wherein, calculated by weight, the raw materials of the reducing glaze include 59-81 parts of flux, 24-30 parts of boron frit, 5-10 parts of kaolin and 0.2-0.8 parts of silicon carbide, and the raw materials of the boron frit include 17-23 parts of borax; (2) performing inkjet printing on the surface of the reduced glaze layer to obtain an inkjet layer; wherein the raw material of the ink used in the inkjet printing step includes a colored metal material; (3) applying a transparent glaze on the surface of the inkjet layer to obtain a glaze layer; (4) placing the bricks coated with transparent glaze in step (3) into a kiln for firing to obtain ceramic tiles having a three-dimensional silk-like dyeing effect; The fluidity of the reducing glaze during firing is greater than the fluidity of the transparent polishing glaze during firing.

2. The method for preparing a ceramic tile having a three-dimensional filamentous dyeing effect according to claim 1, characterized in that: The melting temperature of the reducing glaze is 1100-1150°C, and the melting temperature of the transparent polishing glaze is 1140-1200°C.

3. The method for preparing a ceramic tile having a three-dimensional filamentous dyeing effect according to claim 1, characterized in that: The mesh number of the silicon carbide is greater than 600 meshes.

4. The method for preparing a ceramic tile having a three-dimensional filamentous dyeing effect according to claim 1, characterized in that: Calculated by mass, the raw materials of the boron frit include 17-23 parts of borax, 17-27 parts of albite, 10-16 parts of potassium feldspar, 10-24 parts of wollastonite, 15-21 parts of quartz and 6-14 parts of kaolin.

5. The method for preparing ceramic tiles with three-dimensional filamentous dyeing effect according to claim 1, characterized in that: In step (1), the flux comprises albite, calcined talc, barium carbonate and potassium feldspar, and the raw materials of the reduction glaze comprise, by weight, 27 to 37 parts of albite, 1 to 5 parts of calcined talc, 1 to 3 parts of barium carbonate, 20 to 36 parts of potassium feldspar, 24 to 30 parts of boron frit, 5 to 10 parts of kaolin and 0.2 to 0.8 parts of silicon carbide.

6. The method for preparing ceramic tiles with three-dimensional filamentous dyeing effect according to claim 1, characterized in that: In step (1), reducing glaze is applied to a preset position on the surface of the brick by screen printing.

7. The method for preparing ceramic tiles with three-dimensional filamentous dyeing effect according to claim 1, characterized in that: In step (2), the colored metal material includes any one or more combinations of copper oxide, iron oxide, cobalt oxide and chromium oxide.

8. The method for preparing ceramic tiles with three-dimensional filamentous dyeing effect according to claim 1, characterized in that: The glazing thickness of the reducing glaze layer is 0.02 mm to 0.15 mm, the inkjet thickness of the inkjet layer is 8 to 12 μm, and the glazing thickness of the polishing glaze layer is 0.3 mm to 0.8 mm.

9. The method for preparing a ceramic tile with a three-dimensional filamentous dyeing effect according to claim 4, characterized in that: The method also includes the steps of preparing the boron frit, including: Mix the raw materials of the boron frit according to the proportion; firing the mixed material; After firing, the product is quenched in water to obtain a boron frit; Wherein, the melting temperature curve of the boron frit includes: It takes 80 to 120 minutes to heat up from room temperature to 1100°C. Heating from 1100°C to 1430°C takes 35 to 60 minutes; Keep at 1430℃ for 5~20min.

10. A ceramic tile with a three-dimensional silk-like dyeing effect, characterized in that: The ceramic tile with three-dimensional silk-like dyeing effect is prepared by the preparation method of any one of claims 1 to 9, and comprises a brick blank, a reduction glaze layer, an inkjet layer and a polished glaze layer from bottom to top.

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