A method for manufacturing a ceramic tile having a strong pattern gradation

Abstract

The application relates to the technical field of ceramic tiles, and discloses a preparation method of a ceramic tile with strong pattern level, which comprises the following steps: sequentially applying a surface glaze, a first layer of transition glaze, a second layer of transition glaze and a protective glaze to a body, drying and firing, and grinding and polishing to obtain the ceramic tile with strong pattern level. The ceramic tile prepared by the method has strong pattern level and a decoration effect closer to natural stone, and the design route is in line with the existing ceramic tile process; the reverse idea of the decoration effect and texture from the glaze surface of the ceramic tile downwards is adopted; and a plurality of groups of inkjet and glazing processes are superposed, so that the ceramic tile with more pattern level and a decoration effect more like natural stone is prepared.

Description

Technical Field

[0001] This invention relates to the field of ceramic tile technology, and in particular to a method for preparing ceramic tiles with a strong sense of pattern layering. Background Technology

[0002] Since inkjet printing technology entered China in 2008, it has developed for over a decade. Currently, its application is widespread and the technology is quite mature. This maturity has brought significant convenience to ceramic tile design and development for ceramic enterprises. However, most current tile decorative effects are still focused on single-layer patterns and surface finishes. The inherent decorative effect of tiles still cannot match the deep visual texture and experiential quality of natural stone.

[0003] CN110627510 A discloses a ceramic tile with adjustable three-dimensional pattern and its preparation method. The method employs digital inkjet printing combined with dry glazing technology to prepare a ceramic tile with adjustable three-dimensional pattern, including the following steps: Step 1, preparing a dried blank; Step 2, applying a surface glaze; Step 3, printing color ink; Step 4, printing moisturizing ink; Step 5, printing adhesive ink; Step 6, printing deep-penetrating ink; Step 7, applying dry granules; and Step 8, applying a protective glaze. The moisturizing ink, printed on the glaze surface, prevents rapid penetration and acts as a support for the subsequent adhesive ink, ensuring that the adhesive ink floats on the surface of the moisturizing ink for a longer period, thus allowing for the adhesion of more dry granules and contributing to a very strong three-dimensional effect. The ceramic tile prepared by this method has the advantages of strong three-dimensionality, adjustable three-dimensionality, and the ability to perfectly match the pattern effect.

[0004] CN114315425A discloses a soft-light glazed tile with a skin-like texture and its preparation method. The soft-light glazed tile is made from a body, a soft-light glaze, and a digital protective glaze. The soft-light glaze includes a soft-light glaze material comprising the following components by weight percentage: 30-35% low-melting-point glass powder, 3-5% anorthite, 5-7% wollastonite, 4-7% calcined alumina, 3-6% montmorillonite, 5-8% magnesite, 3-6% calcined zinc oxide, 15-25% soft-light frit, and 14-18% zirconium silicate. The soft-light frit comprises the following components by weight percentage: 5-8% alumina, 12-16% quartz, 25-29% potassium feldspar, 22-28% calcite, 16-20% barium carbonate, and 9-12% nepheline. This soft-light glazed tile combines the soft-light glaze with a digital protective glaze, resulting not only in a good soft-light effect but also in a delicate and smooth glaze texture, achieving a skin-like feel, and significantly reducing tile deformation.

[0005] CN112358326A discloses a method for preparing a matte, deeply engraved ceramic tile and the ceramic tile itself. The method for preparing the ceramic tile includes: pressing a green body and drying it; spraying water onto the green body and applying a base glaze; maintaining the green body temperature at 40-45℃; and printing digital mold ink, wherein the ink volume of the digital mold ink is 15-78 g / m³. 2 Furthermore, the digital mold ink is a matte oil-based ceramic ink; after drying, a high-pressure spray glaze is applied using a reciprocating spraying method, with the surface glaze having a specific gravity of 1.5-1.52 g / cm³. 3 Glazing amount is 800-1000g / m² 2 The process involves inkjet printing the pattern, followed by printing digital matte and glossy protective glaze inks; drying and high-temperature firing; light polishing and edge grinding to obtain the ceramic tile. This method enables ceramic tiles to form deeper, finer, and more realistic textures, with an adjustable engraving depth of 0.1-5mm. It is also more intelligent and convenient, resulting in beautiful, natural, and lifelike ceramic tiles.

[0006] The above inventions are characterized by printing only one layer of decorative pattern, and then applying different decorative effects on top of the pattern. Dry granulation or fine carving techniques can be used to achieve some special decorative effects, but they still cannot replicate the rich color and pattern texture and layered effect of natural stone. Multi-layered decorative effects require very strict requirements for pattern design and matching. Furthermore, the use of multiple layers of glaze requires high standards for controlling the glaze ratio, the selection of glaze raw materials, and the control of glaze thickness. The glaze layer cannot be too thin, otherwise it will be difficult to polish, easily worn through, and the product will be downgraded; it also cannot be too thick, as it is prone to air bubbles, poor transparency, and difficulty in controlling the tile shape. Summary of the Invention

[0007] The purpose of this invention is to overcome at least one deficiency of the prior art and provide a method for preparing ceramic tiles with strong pattern layering.

[0008] The technical solution adopted in this invention is:

[0009] This invention provides a method for preparing ceramic tiles with strong pattern layering, comprising the following steps:

[0010] 1) Apply a surface glaze to the blank to obtain a surface glaze layer, and then spray ink onto the surface glaze layer to obtain the first layer of colored ink.

[0011] 2) After applying the first transition glaze to the first color ink layer obtained in step 1), dry and spray ink to obtain the second color ink layer;

[0012] 3) After applying the second transition glaze to the second color ink layer obtained in step 2), dry and spray ink to obtain the third color ink layer;

[0013] 4) After applying a protective glaze to the third layer of color ink obtained in step 3), dry and fire it, then grind and polish the edges to obtain a ceramic tile with a strong sense of pattern layering.

[0014] In some instances, the specific gravity of the glaze is 1.82 g / cm³. 3 ~1.92g / cm 3 The amount of glaze applied is 450g / m². 2 ~600g / m 2 .

[0015] In some instances, the glaze comprises the following components by weight percentage:

[0016] Sodium feldspar 20-40%;

[0017] Potassium feldspar 15-25%;

[0018] Quartz 15-30%;

[0019] 1-10% calcined clay;

[0020] Kaolin content 5-15%;

[0021] Calcinated zinc oxide 1-10%;

[0022] Calcinated alumina 1-20%;

[0023] Barium carbonate 5-15%;

[0024] Zirconium silicate 5-10%.

[0025] In some instances, the glaze comprises the following components by weight percentage:

[0026] Sodium feldspar 20-28%;

[0027] Potassium feldspar 15-18%;

[0028] Quartz 15-16%;

[0029] 3-5% calcined clay;

[0030] Kaolin 5-8%;

[0031] Calcinated zinc oxide 4-10%;

[0032] 5-11% calcined alumina;

[0033] Barium carbonate 5-6%;

[0034] Zirconium silicate 7-10%.

[0035] In some instances, the specific gravity of the first transition glaze layer is 1.82 g / cm³.3 ~1.92g / cm 3 The amount of the first transition glaze applied is 400g / m². 2 ~500g / m 2 .

[0036] In some instances, the specific gravity of the second transition glaze layer is 1.82 g / cm³. 3 ~1.92g / cm 3 The amount of the second transition glaze applied is 400g / m². 2 ~500g / m 2 .

[0037] In some instances, a protective glaze is applied using a pouring method, the specific gravity of which is 1.82 g / cm³. 3 ~1.92g / cm 3 The amount of the protective glaze applied is 500g / m². 2 ~600g / m 2 .

[0038] In some instances, when a protective glaze is applied by spraying, the specific gravity of the protective glaze is 1.35 g / cm³. 3 ~1.45g / cm 3 The amount of the protective glaze applied is 550 g / m³. 2 ~700g / m 2 .

[0039] In some instances, the first transition glaze, the second transition glaze, and the protective glaze comprise the following components by weight percentage:

[0040] Sodium feldspar 20-40%;

[0041] Potassium feldspar 15-25%;

[0042] Quartz 1-30%;

[0043] 5-15% calcined clay;

[0044] Kaolin content: 5-10%;

[0045] Calcite 1-10%;

[0046] Dolomite 1-20%;

[0047] Calcinated zinc oxide 1-10%;

[0048] Alumina 1-10%;

[0049] Burnt talc 1-10%;

[0050] Barium carbonate 1-10%;

[0051] Strontium carbonate 1-10%.

[0052] In some instances, the first transition glaze layer comprises the following components by weight percentage:

[0053] Sodium feldspar 20-26%;

[0054] Potassium feldspar 15-20%;

[0055] Quartz 1-3%;

[0056] 5-8% calcined clay;

[0057] Kaolin 5-8%;

[0058] Calcite 2-9%;

[0059] Dolomite 1-15%;

[0060] Calcination of zinc oxide: 3-10%;

[0061] Alumina 2-9%;

[0062] Burn talc to 7-8%;

[0063] Barium carbonate 3-9%;

[0064] Strontium carbonate 5-8%.

[0065] In some instances, the second transition glaze comprises the following components by weight percentage:

[0066] Sodium feldspar 27-28%;

[0067] Potassium feldspar 19-20%;

[0068] Quartz 2-3%;

[0069] Calcinated clay 6-8%;

[0070] Kaolin 7-8%;

[0071] 2-3% calcite;

[0072] Dolomite 13-14%;

[0073] Calcination of zinc oxide 2-3%;

[0074] Alumina 2-3%;

[0075] Calcined talc 6-7%;

[0076] Barium carbonate 2-3%;

[0077] Strontium carbonate 5-6%.

[0078] In some instances, the protective glaze comprises the following components by weight percentage:

[0079] Sodium feldspar 29-30%;

[0080] Potassium feldspar 17-18%;

[0081] Quartz 17-18%;

[0082] 5-6% calcined clay;

[0083] Kaolin 6-7%;

[0084] Calcite 1-3%;

[0085] Dolomite 12-19%;

[0086] Calcination of zinc oxide: 3-10%;

[0087] Alumina 1-2%;

[0088] Burnt talc 1-7%;

[0089] Barium carbonate 1-3%;

[0090] Strontium carbonate 1-6%.

[0091] In some instances, the drying temperature in steps 2), 3), and 4) is 150–200°C.

[0092] In some instances, the firing temperature in step 4) is 1100–1200°C.

[0093] The beneficial effects of this invention are:

[0094] The ceramic tiles prepared by this invention have a strong sense of layering in their patterns, resulting in a decorative effect that more closely resembles natural stone. This invention differs from existing ceramic tile manufacturing processes and adopts a reverse approach, working downwards towards the glaze surface to create decorative effects and textures. It utilizes multiple inkjet printing and glazing processes to create ceramic tiles with greater pattern layering and a decorative effect more like natural stone. Attached Figure Description

[0095] Figure 1 This is a picture of the ceramic brick prepared in Example 1 of the present invention.

[0096] Figure 2 This is a picture of the ceramic brick prepared in Example 2 of the present invention.

[0097] Figure 3 This is a picture of the ceramic brick prepared in Example 3 of the present invention.

[0098] Figure 4 This is a picture of the ceramic brick prepared according to Comparative Example 1 of the present invention.

[0099] Figure 5 This is a picture of the ceramic brick prepared in Comparative Example 2 of the present invention.

[0100] Figure 6 This is a picture of the ceramic brick prepared in Comparative Example 3 of this invention. Detailed Implementation

[0101] The following disclosure provides many different implementations or examples for different ways of implementing the present invention.

[0102] The preparation method of ceramic tiles with strong pattern layering in the various embodiments and comparative examples of the present invention includes the following steps:

[0103] Step 1: Pressing the powder into a blank. The powder is pressed into a blank using a press.

[0104] Step 2: Apply surface glaze. Apply surface glaze to the body from Step 1 to obtain a surface glaze layer.

[0105] Step 3: Inkjet printing of colored ink. According to the designed pattern, print colored ceramic ink on the glaze layer obtained in Step 2 to obtain the first layer of colored ink.

[0106] Step 4: Drying. The brick blanks obtained in Step 3 are dried.

[0107] Step 5: Apply the first transition glaze layer. Apply glaze to the brick blanks dried in Step 4, and apply the first transition glaze layer.

[0108] Step 6: Drying. The brick blanks obtained in Step 5 are dried.

[0109] Step 7: Inkjet print colored ink. According to the designed pattern, print colored ceramic ink on the first transition glaze layer obtained in Step 6 to obtain the second colored ink layer.

[0110] Step 8: Apply the second transition glaze layer. Apply glaze to the brick blank after printing the second layer of color ink in Step 7, and apply the second transition glaze layer.

[0111] Step 9: Drying. The brick blanks obtained in Step 8 are dried.

[0112] Step 10: Print color ink or functional ceramic ink on the second transition glaze layer obtained in step 9 according to the designed pattern to obtain the third ink layer.

[0113] Step 11: Apply protective glaze. Apply glaze to the brick blank after printing the third ink layer in Step 10, and apply the final protective glaze layer.

[0114] Step 12: Drying. Dry the brick blanks obtained in Step 11 at 200℃ for 10 minutes.

[0115] Step 13: Firing. The brick blanks obtained in Step 12 are fired at 1160℃ for 60 minutes.

[0116] Step Fourteen: Edge Grinding and Polishing. The ceramic tiles fired in Step Thirteen are polished and ground to obtain ceramic tiles.

[0117] Example 1

[0118] The mass percentage composition of the top glaze, the first transition glaze, the second transition glaze, and the protective glaze is shown in Table 1 below.

[0119] Table 1

[0120] Mass content (%) Surface glaze First layer of transition glaze Second layer of transition glaze Protective glaze Sodium feldspar 28 25 27 29 Potassium feldspar 15 20 20 18 quartz 16 2 3 5 Calcinated soil 5 8 7 5 Kaolin 6 8 8 7 calcite 0 2 2 3 dolomite 0 15 13 13 Calcination of zinc oxide 4 3 3 3 Calcinated alumina 11 0 0 0 Alumina 0 2 2 2 Burning talc 2 7 7 7 Barium carbonate 6 3 3 3 Strontium carbonate 0 5 5 5 Zirconium silicate 7 0 0 0

[0121] The surface glaze is applied using a pouring method, and the specific gravity of the surface glaze is 1.9 g / cm³. 3 The amount of glaze applied is 550g / m². 2 .

[0122] In step four, the drying temperature is controlled at 200℃ and the drying time is 3 minutes.

[0123] The first transition glaze layer was applied using a pouring method, and the specific gravity of this first transition glaze layer was 1.9 g / cm³. 3 The amount of glaze applied to the first transition glaze layer is 400g / m². 2 .

[0124] In step six, the drying temperature is controlled at 200℃ and the drying time is 5 minutes.

[0125] The second transition glaze is applied using a pouring method, and the specific gravity of the glaze in this second transition glaze layer is 1.9 g / cm³. 3 The amount of glaze applied to the second transition glaze layer is 400g / m². 2 .

[0126] In step nine, the drying temperature is controlled at 200℃ and the drying time is 7 minutes.

[0127] The protective glaze is applied using a pouring method, and the specific gravity of the glaze layer is 1.85 g / cm³. 3 Glazing amount is 500g / m 2 .

[0128] Example 1: Ceramic tiles with strong pattern layering after firing, such as... Figure 1 As shown.

[0129] Example 2

[0130] The mass percentage composition of the top glaze, the first transition glaze, the second transition glaze, and the protective glaze in this embodiment is shown in Table 2 below, and the other parameters are the same as in Example 1.

[0131] Table 2

[0132] Mass content (%) Surface glaze First layer of transition glaze Second layer of transition glaze Protective glaze Sodium feldspar 25 26 28 30 Potassium feldspar 18 19 20 17 quartz 16 3 3 4 Calcinated soil 3 7 6 6 Kaolin 8 7 8 7 calcite 0 3 2 3 dolomite 0 14 13 12 Calcination of zinc oxide 5 4 3 4 Calcinated alumina 10 0 0 0 Alumina 0 2 2 1 Burning talc 3 7 6 7 Barium carbonate 5 3 3 3 Strontium carbonate 0 5 6 6 Zirconium silicate 7 0 0 0

[0133] In this embodiment, the fired ceramic tiles exhibit a strong sense of pattern layering, such as... Figure 2 As shown.

[0134] Example 3

[0135] The mass percentage composition of the top glaze, the first transition glaze, the second transition glaze, and the protective glaze in this embodiment is shown in Table 3 below, and the remaining parameters are the same as in Example 1.

[0136] Table 3

[0137] Mass content (%) Surface glaze First layer of transition glaze Second layer of transition glaze Protective glaze Sodium feldspar 20 20 27 30 Potassium feldspar 15 15 20 18 quartz 15 1 3 7 Calcinated soil 5 5 7 5 Kaolin 5 5 8 6 calcite 0 9 2 1 dolomite 0 1 13 19 Calcination of zinc oxide 10 10 3 10 Calcinated alumina 5 0 0 0 Alumina 0 9 2 1 Burning talc 10 8 7 1 Barium carbonate 5 9 3 1 Strontium carbonate 0 8 5 1 Zirconium silicate 10 0 0 0

[0138] In this embodiment, the fired ceramic tiles exhibit a strong sense of pattern layering, such as... Figure 3 As shown.

[0139] Comparative Example 1

[0140] The composition of the top glaze, first transition glaze, second transition glaze, and protective glaze in this comparative example is the same as that in Example 1, and the remaining parameters are as follows:

[0141] The surface glaze is applied using a pouring method, and the specific gravity of the surface glaze is 1.9 g / cm³. 3 The amount of glaze applied is 550g / m². 2 .

[0142] In step four, the drying temperature is controlled at 200℃ and the drying time is 3 minutes.

[0143] The first transition glaze layer was applied using a pouring method, and the specific gravity of this first transition glaze layer was 1.9 g / cm³. 3 The amount of glaze applied to the first transition glaze layer is 550 g / m³. 2 .

[0144] In step six, the drying temperature is controlled at 200℃ and the drying time is 5 minutes.

[0145] The second transition glaze is applied using a pouring method, and the specific gravity of the glaze in this second transition glaze layer is 1.9 g / cm³. 3 The amount of glaze applied to the second transition glaze layer is 400g / m².2 .

[0146] In step nine, the drying temperature is controlled at 200℃ and the drying time is 7 minutes.

[0147] In step ten, the ink combination is a combination of conventional color inks plus recessed ceramic ink.

[0148] The protective glaze is applied using a pouring method, and the specific gravity of the glaze layer is 1.9 g / cm³. 3 Glazing amount is 500g / m 2 Comparative Example 1: The fired ceramic tiles, such as... Figure 4 As shown.

[0149] Comparative Example 2

[0150] The composition of the top glaze, first transition glaze, second transition glaze, and protective glaze in this comparative example is the same as that in Example 1, and the remaining parameters are as follows:

[0151] The surface glaze is applied using a pouring method, and the specific gravity of the surface glaze is 1.9 g / cm³. 3 The amount of glaze applied is 550g / m². 2 .

[0152] In step four, the drying temperature is controlled at 200℃ and the drying time is 3 minutes.

[0153] The first transition glaze layer was applied using a pouring method, and the specific gravity of this first transition glaze layer was 1.9 g / cm³. 3 The amount of glaze applied to the first transition glaze layer is 550 g / m³. 2 .

[0154] In step six, the drying temperature is controlled at 200℃ and the drying time is 5 minutes.

[0155] The second transition glaze is applied using a pouring method, and the specific gravity of the glaze in this second transition glaze layer is 1.9 g / cm³. 3 The amount of glaze applied to the second transition glaze layer is 550g / m². 2 .

[0156] In step nine, the drying temperature is controlled at 200℃ and the drying time is 7 minutes.

[0157] In step ten, the ink combination is a combination of conventional color inks plus recessed ceramic ink.

[0158] The protective glaze is applied using a pouring method, and the specific gravity of the glaze layer is 1.9 g / cm³. 3Glazing amount is 500g / m 2 Comparative Example 2: The fired ceramic tiles are as follows. Figure 5 As shown.

[0159] Comparative Example 3

[0160] The composition of the top glaze, first transition glaze, second transition glaze, and protective glaze in this comparative example is the same as that in Example 1, and the remaining parameters are as follows:

[0161] The surface glaze is applied using a pouring method, and the specific gravity of the surface glaze is 1.9 g / cm³. 3 The amount of glaze applied is 550g / m². 2 .

[0162] In step four, the drying temperature is controlled at 200℃ and the drying time is 3 minutes.

[0163] The first transition glaze layer was applied using a pouring method, and the specific gravity of this first transition glaze layer was 1.9 g / cm³. 3 The amount of glaze applied to the first transition glaze layer is 550 g / m³. 2 .

[0164] In step six, the drying temperature is controlled at 200℃ and the drying time is 5 minutes.

[0165] The second transition glaze is applied using a pouring method, and the specific gravity of the glaze in this second transition glaze layer is 1.9 g / cm³. 3 The amount of glaze applied to the second transition glaze layer is 550g / m². 2 .

[0166] In step nine, the drying temperature is controlled at 200℃ and the drying time is 7 minutes.

[0167] In step ten, the ink combination is a combination of conventional color inks plus recessed ceramic ink.

[0168] The protective glaze is applied using a pouring method, and the specific gravity of the glaze layer is 1.9 g / cm³. 3 Glazing amount is 650g / m 2 Comparative Example 3: The fired ceramic tiles, such as... Figure 6 As shown.

[0169] As can be seen from the effect pictures of Examples 1 to 3, ceramic tiles with a strong sense of layering can be obtained within the composition range of the surface glaze, the first transition glaze, the second transition glaze, and the protective glaze within the scope of the present invention.

[0170] As can be seen from the effect images of Comparative Examples 1 to 3, as the amount of glaze applied increases, the clarity of the pattern gradually becomes blurred, and the transparency of the glaze layer gradually deteriorates.

[0171] The above is a further detailed description of the present invention and should not be considered as a limitation on the specific implementation of the present invention. For those skilled in the art, simple deductions or substitutions without departing from the concept of the present invention are all within the protection scope of the present invention.

Claims

1. A method for manufacturing a ceramic tile having a strong pattern gradation, characterized by, The method comprises the following steps: 1) applying a surface glaze to the body to obtain a surface glaze layer, and then jetting ink on the surface glaze layer to obtain a first color ink layer; 2) applying a first transition glaze to the first color ink layer obtained in step 1), and then drying and jetting ink to obtain a second color ink layer; 3) applying a second transition glaze to the second color ink layer obtained in step 2), and then drying and jetting ink to obtain a third color ink layer; 4) applying a protective glaze to the third color ink layer obtained in step 3), and then drying, firing, edge grinding and polishing to obtain a ceramic tile with strong pattern gradation; The specific gravity of the surface glaze is 1.82 g / cm 3 ~ 1.92 g / cm 3 The application amount of the surface glaze is 450 g / m 2 ~ 600 g / m 2 The composition of the surface glaze by weight percentage is: albite 20-40%; potash feldspar 15-25%; quartz 15-30%; calcined clay 1-10%; kaolin 5-15%; calcined zinc oxide 1-10%; calcined alumina 1-20%; barium carbonate 5-15%; zirconium silicate 5-10%; the first transition glaze, the second transition glaze and the protective glaze each comprise the following components by weight percentage: albite 20-40%; potash feldspar 15-25%; quartz 1-30%; calcined clay 5-15%; kaolin 5-10%; calcite 1-10%; dolomite 1-20%; calcined zinc oxide 1-10%; alumina 1-10%; calcined talc 1-10%; barium carbonate 1-10%; strontium carbonate 1-10%; The specific gravity of the first layer of transition glaze is 1.82g / cm 3 ~1.92g / cm 3 The application amount of the first layer of transition glaze is 400g / m 2 ~500g / m 2 The specific gravity of the second layer of transition glaze is 1.82g / cm 3 ~1.92g / cm 3 The application amount of the second layer of transition glaze is 400g / m 2 ~500g / m 2 .

2. The production method according to claim 1, characterized by, A protective glaze is applied in the form of a glaze spray, the specific gravity of the protective glaze being 1.82 g / cm 3 ~ 1.92 g / cm 3 , the application amount of the protective glaze being 500 g / m 2 ~ 600 g / m 2 .

3. The preparation method according to claim 1, characterized in that, When the protective glaze is applied by spraying, the specific gravity of the protective glaze is 1.35 g / cm 3 ~ 1.45 g / cm 3 , the application amount of the protective glaze is 550 g / m 2 ~ 700 g / m 2 .

4. The method of claim 1, wherein, the drying temperature of steps 2), 3) and 4) is 150-200℃.

5. The preparation method according to claim 1, characterized in that, the firing temperature in step 4) is 1100-1200℃.

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