A non-slip and stain-resistant antique-style brick and its preparation method

Abstract

A non-slip and stain-resistant antique-style brick and its preparation method are disclosed. The brick comprises a body and a glaze layer covering the surface of the body. The glaze layer, from the inside out, includes a pattern layer and a non-slip glaze layer. A raised layer is provided on the surface of the non-slip glaze layer. The raised layer is made of red clay, kaolin, and lava particles. Red clay and kaolin form the raised base layer in a ratio of 60-90:40-10, and the lava particles are disposed on the raised base layer. The raw materials of the non-slip glaze layer consist of an effect glaze and non-slip powder. The raw materials of the effect glaze include the following components by weight: 15-25 parts albite, 15-25 parts wollastonite, 4-8 parts calcite, 2-5 parts quartz, and 8-12 parts barium carbonate. The antique-style brick of this invention possesses both high non-slip performance and excellent stain resistance. The preparation method is simple, easy to operate, and low in cost.

Description

Technical Field

[0001] This invention belongs to the field of antique brick technology, specifically relating to an anti-slip and anti-fouling antique brick and its preparation method. Background Technology

[0002] Traditional ceramic production often uses raw materials extracted from mines, such as potassium, sodium, and aluminum oxide powders. This method is not only costly but also limited by the abundance of raw material resources. With the development of technology and increasing environmental protection requirements, people have begun to look for more economical and environmentally friendly production methods.

[0003] Against this backdrop, utilizing granite waste and locally unique raw materials (such as feldspar with specific iron and silicon content, sand with specific iron content, and clay and red clay with specific iron and aluminum content) as raw materials for manufacturing antique-style bricks has become a new production method. This method not only solves the environmental pollution and resource waste problems caused by the discharge of large amounts of granite waste, but also realizes waste utilization, providing a new and resource-rich raw material for ceramic production.

[0004] In addition, the production of modern antique-style bricks also incorporates advanced technology and equipment, such as granite grinding machines, molding machines, drying chambers, and kilns. Through processes such as material proportioning, powder making, pressing and molding, glazing and printing, firing, and edge grinding, antique-style bricks with a rustic and classic style are produced.

[0005] However, currently, very few antique-style tiles on the market have a slip resistance coefficient of R10-R11. The vast majority of antique-style tiles have poor slip resistance, posing significant safety hazards. Anti-slip ceramic tiles on the market are mainly achieved by spraying or applying anti-slip agents or corrosive agents, or by using special materials and embossed molds to create an uneven surface. The disadvantage of this method is that once the slip resistance coefficient reaches R10-R11, the stain resistance becomes poor, and these processes also reduce the clarity of inkjet patterns, affecting aesthetics. Summary of the Invention

[0006] In order to overcome the shortcomings of the prior art, one of the objectives of this invention is to provide a non-slip and stain-resistant antique-style brick.

[0007] The second objective of this invention is to provide a method for preparing anti-slip and stain-resistant antique-style bricks, which is applicable to standardized mass production and produces anti-slip and stain-resistant antique-style bricks.

[0008] A non-slip and stain-resistant antique-style tile includes a body and a glaze layer covering the surface of the body. The glaze layer comprises a pattern layer and a non-slip glaze layer from the inside out. The surface of the non-slip glaze layer is provided with a raised layer. Its characteristics are:

[0009] The raised layer is made of red clay, kaolin, and lava particles; wherein the red clay and kaolin form the raised base layer in a ratio of 60-90:40-10, and the lava particles are disposed on the raised base layer;

[0010] The anti-slip glaze layer is composed of effect glaze and anti-slip powder; the effect glaze comprises the following components by weight:

[0011] 15-25 parts of albite, 15-25 parts of wollastonite, 4-8 parts of calcite, 2-5 parts of quartz, and 8-12 parts of barium carbonate.

[0012] Furthermore, the chemical composition of the effect glaze includes: SiO2 40-49%, Al2O3 10-13%, Fe2O3 0-1%, TiO2 0-0.3%, CaO 2-8%, MgO 1-7%, K2O 2-6%, Na2O 1-5%, ZnO 2-4.5%, BaO 6-12%, ZrO2 5-7%, and loss on ignition 3-5.5%.

[0013] Further, the chemical composition of the green body includes: SiO2 66-69%, Al2O3 19.5-20.5%, Fe2O3 0.5-1.5%, TiO2 0.1-0.5%, CaO 0.3-1%, MgO 0.3-1%, K2O 2.5-3.5%, Na2O 1.5-2.5%, and loss on ignition 1-5%.

[0014] Furthermore, a method for preparing antique-style bricks is characterized by comprising the following steps:

[0015] S1, Preparation of the green body;

[0016] S2, apply an anti-slip glaze to the surface of the blank to form a patterned base layer;

[0017] S3, Inkjet printing a pattern onto the pattern base layer to form a pattern layer;

[0018] S4, an anti-slip glaze layer is formed on the pattern layer;

[0019] S5, the raw materials of red clay and kaolin in a ratio of 60-90:40-10 are mixed, stirred and physicochemically treated, and the mixture is applied to the blank obtained in step S4.

[0020] S6, lava particles are partially embedded in the upper layer of the blank obtained in step S5 under pressure; then it is shaped, dried and fired to produce antique bricks.

[0021] Further, in step S1, the specific steps are as follows: take the raw material of the billet and 1.5-2.5% of the billet auxiliary material by weight, add water and mix, ball mill, pass through a 240-260 mesh sieve to form a billet slurry with a sieve residue weight percentage of 0.8-1.2% and a moisture content of 35-38%, remove iron, sieve, spray dry, press into shape, dry, and obtain the billet; the billet auxiliary material is sodium tripolyphosphate and / or sodium metasilicate pentahydrate.

[0022] Further, in step S2, the preparation method of the anti-slip glaze is as follows: take the raw materials of the anti-slip glaze layer in the formula amount, add water and mix, ball mill, pass through a 320-330 mesh sieve to form an anti-slip glaze slurry with a sieve residue mass percentage of 0.3-0.5% and a water content of 31-37%, remove iron, and sieve to obtain the anti-slip glaze.

[0023] Furthermore, in step S6, the firing temperature is 1235–1300℃, and the firing time is 66–100 min.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0025] The raised layer in this invention is made of red clay, kaolin, and lava particles, and has excellent anti-slip and anti-fouling properties. Moreover, the preparation method is simple and the cost is low. Attached Figure Description

[0026] Figure 1 This is a process flow diagram of the present invention. Detailed Implementation

[0027] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments. It should be noted that, without conflict, the various embodiments or technical features described below can be arbitrarily combined to form new embodiments.

[0028] Example 1

[0029] A non-slip and stain-resistant antique-style tile includes a body and a glaze layer covering the surface of the body. The glaze layer comprises a pattern layer and a non-slip glaze layer from the inside out. The surface of the non-slip glaze layer is provided with a raised layer. Its characteristics are:

[0030] The raised layer is made of red clay, kaolin, and lava particles; wherein the red clay and kaolin form the raised base layer in a ratio of 60-90:40-10, and the lava particles are disposed on the raised base layer;

[0031] The anti-slip glaze layer is composed of effect glaze and anti-slip powder; the effect glaze comprises the following components by weight:

[0032] 15 parts albite, 15 parts wollastonite, 4 parts calcite, 2 parts quartz, and 8 parts barium carbonate.

[0033] In this embodiment, the chemical composition of the effect glaze includes: SiO2 40%, Al2O3 103%, Fe2O3 0.1%, TiO2 0.1%, CaO 2%, MgO 1%, K2O 2%, Na2O 1%, ZnO 2%, BaO 6%, ZrO 25%, and loss on ignition 3%.

[0034] In this embodiment, the composition is 66% SiO2, 19.5% Al2O3, 0.5% Fe2O3, 0.1% TiO2, 0.3-1% CaO, 0.3% MgO, 2.5% K2O, 1.5% Na2O, and 1% loss on ignition.

[0035] A method for preparing antique-style bricks, characterized by comprising the following steps:

[0036] S1, Preparation of the green body;

[0037] S2, apply an anti-slip glaze to the surface of the blank to form a patterned base layer;

[0038] S3, Inkjet printing a pattern onto the pattern base layer to form a pattern layer;

[0039] S4, an anti-slip glaze layer is formed on the pattern layer;

[0040] S5, the raw materials of red clay and kaolin in a ratio of 60:40 are mixed, stirred and physicochemically treated, and the mixture is applied to the blank obtained in step S4.

[0041] S6, lava particles are partially embedded in the upper layer of the blank obtained in step S5 under pressure; then it is shaped, dried and fired to produce antique bricks.

[0042] In this embodiment, step S1 specifically involves: taking raw materials for the billet and 1.5% of the billet's mass of auxiliary materials, adding water and mixing, ball milling, passing through a 240-mesh sieve to form a billet slurry with a sieve residue mass percentage of 0.8% and a moisture content of 35%, removing iron, sieving, spray drying, pressing and molding, drying, and obtaining the billet; the auxiliary materials for the billet are sodium tripolyphosphate and / or sodium metasilicate pentahydrate.

[0043] Further, in step S2, the preparation method of the anti-slip glaze is as follows: take the raw materials of the anti-slip glaze layer in the formula amount, add water and mix, ball mill, pass through a 320 mesh sieve to form an anti-slip glaze slurry with a sieve residue mass percentage of 0.3% and a water content of 31%, remove iron, pass through a sieve, and obtain the anti-slip glaze.

[0044] In this embodiment, in step S6, the firing temperature is 1235°C and the firing time is 66 minutes.

[0045] Example 2

[0046] A non-slip and stain-resistant antique-style tile includes a body and a glaze layer covering the surface of the body. The glaze layer comprises a pattern layer and a non-slip glaze layer from the inside out. The surface of the non-slip glaze layer is provided with a raised layer. Its characteristics are:

[0047] The raised layer is made of red clay, kaolin, and lava particles; wherein the red clay and kaolin form the raised base layer in a ratio of 90:10, and the lava particles are disposed on the raised base layer;

[0048] The anti-slip glaze layer is composed of effect glaze and anti-slip powder; the effect glaze comprises the following components by weight:

[0049] 25 parts albite, 25 parts wollastonite, 8 parts calcite, 5 parts quartz, and 12 parts barium carbonate.

[0050] In this embodiment, the chemical composition of the effect glaze includes: SiO2 49%, Al2O3 13%, Fe2O3 1%, TiO2 0.3%, CaO 8%, MgO 7%, K2O 6%, Na2O 5%, ZnO 4.5%, BaO 12%, ZrO2 7%, and loss on ignition 5.5%.

[0051] In this embodiment, the chemical composition of the blank includes: SiO2 69%, Al2O3 20.5%, Fe2O3 1.5%, TiO2 0.5%, CaO 1%, MgO 1%, K2O 3.5%, Na2O 2.5%, and loss on ignition 5%.

[0052] A method for preparing antique-style bricks includes the following steps:

[0053] S1, Preparation of the green body;

[0054] S2, apply an anti-slip glaze to the surface of the blank to form a patterned base layer;

[0055] S3, Inkjet printing a pattern onto the pattern base layer to form a pattern layer;

[0056] S4, an anti-slip glaze layer is formed on the pattern layer;

[0057] S5, the raw materials of red clay and kaolin in a ratio of 90:10 are mixed, stirred and physicochemically treated, and the mixture is applied to the blank obtained in step S4.

[0058] S6, lava particles are partially embedded in the upper layer of the blank obtained in step S5 under pressure; then it is shaped, dried and fired to produce antique bricks.

[0059] In this embodiment, step S1 specifically involves: taking raw materials for the billet and 2.5% of the billet's mass of auxiliary materials, adding water and mixing, ball milling, passing through a 260-mesh sieve to form a billet slurry with a sieve residue mass percentage of 1.2% and a moisture content of 38%, removing iron, sieving, spray drying, pressing and molding, drying to obtain the billet; the auxiliary materials for the billet are sodium tripolyphosphate and / or sodium metasilicate pentahydrate.

[0060] In this embodiment, in step S2, the preparation method of the anti-slip glaze is as follows: take the raw materials of the anti-slip glaze layer in the formula amount, add water and mix, ball mill, pass through a 330 mesh sieve to form an anti-slip glaze slurry with a sieve residue mass percentage of 0.5% and a water content of 37%, remove iron, pass through a sieve, and obtain the anti-slip glaze.

[0061] In this embodiment, in step S6, the firing temperature is 1300℃ and the firing time is 100min.

[0062] Example 3

[0063] A non-slip and stain-resistant antique-style brick includes a body and a glaze layer covering the surface of the body. The glaze layer includes a pattern layer and a non-slip glaze layer from the inside out. The surface of the non-slip glaze layer is provided with a raised layer. The raised layer is made of red clay, kaolin, and lava particles. The red clay and kaolin form the raised base layer in a ratio of 70:30, and the lava particles are disposed on the raised base layer.

[0064] The anti-slip glaze layer is composed of effect glaze and anti-slip powder; the effect glaze comprises the following components by weight:

[0065] 20 parts albite, 20 parts wollastonite, 7 parts calcite, 4 parts quartz, and 10 parts barium carbonate.

[0066] In this embodiment, the chemical composition of the effect glaze includes: SiO2 45%, Al2O3 101%, Fe2O3 0.5%, TiO2 0.2%, CaO 4%, MgO 4%, K2O 4%, Na2O 3%, ZnO 3.5%, BaO 8%, ZrO 26%, and loss on ignition 4%.

[0067] In this embodiment, the chemical composition of the blank includes: SiO2 68%, Al2O3 20%, Fe2O3 1%, TiO2 0.3%, CaO 0.6%, MgO 0.5%, K2O 3%, Na2O 2%, and loss on ignition 3%.

[0068] A method for preparing antique-style bricks, referenced Figure 1 This includes the following steps:

[0069] S1, Preparation of the green body;

[0070] S2, apply an anti-slip glaze to the surface of the blank to form a patterned base layer;

[0071] S3, Inkjet printing a pattern onto the pattern base layer to form a pattern layer;

[0072] S4, an anti-slip glaze layer is formed on the pattern layer;

[0073] S5, the raw materials of red clay and kaolin in a ratio of 60-90:40-10 are mixed, stirred and physicochemically treated, and the mixture is applied to the blank obtained in step S4.

[0074] S6, lava particles are partially embedded in the upper layer of the blank obtained in step S5 under pressure; then it is shaped, dried and fired to produce antique bricks.

[0075] In this embodiment, step S1 specifically involves: taking raw materials for the billet and 2% of the billet mass of auxiliary materials for the billet, adding water and mixing, ball milling, passing through a 250-mesh sieve to form a billet slurry with a sieve residue mass percentage of 1% and a moisture content of 37%, removing iron, sieving, spray drying, pressing and molding, drying to obtain the billet; the auxiliary materials for the billet are sodium tripolyphosphate and / or sodium metasilicate pentahydrate.

[0076] In this embodiment, in step S2, the preparation method of the anti-slip glaze is as follows: take the raw materials of the anti-slip glaze layer in the formula amount, add water and mix, ball mill, pass through a 325 mesh sieve to form an anti-slip glaze slurry with a sieve residue mass percentage of 0.4% and a water content of 34%, remove iron, pass through a sieve, and obtain the anti-slip glaze.

[0077] In this embodiment, in step S6, the firing temperature is 1265°C and the firing time is 80 minutes.

[0078] The above embodiments are merely preferred embodiments of the present invention and should not be construed as limiting the scope of protection of the present invention. Any non-substantial changes and substitutions made by those skilled in the art based on the present invention shall fall within the scope of protection claimed by the present invention.

Claims

1. A non-slip and stain-resistant antique-style tile, comprising a body and a glaze layer covering the surface of the body, wherein the glaze layer comprises, from the inside out, a pattern layer and a non-slip glaze layer; the surface of the non-slip glaze layer is provided with a raised layer; characterized in that: The raised layer is made of red clay, kaolin, and lava particles; wherein the red clay and kaolin form the raised base layer in a ratio of 60-90:40-10, and the lava particles are disposed on the raised base layer; The anti-slip glaze layer is composed of effect glaze and anti-slip powder; the effect glaze comprises the following components by weight: 15-25 parts of albite, 15-25 parts of wollastonite, 4-8 parts of calcite, 2-5 parts of quartz, and 8-12 parts of barium carbonate. The preparation method of the anti-slip and stain-resistant antique-style bricks includes the following steps: S1, Preparation of the green body; S2, apply an anti-slip glaze to the surface of the blank to form a patterned base layer; S20, inkjet printing a pattern onto the pattern base layer to form a pattern layer; S4, an anti-slip glaze layer is formed on the pattern layer; S5, the raw materials of red clay and kaolin are mixed in a ratio of 60-90:40-10, stirred and physicochemically treated, and the mixture is applied to the blank obtained in step S4; S6, lava particles are partially embedded in the upper layer of the blank obtained in step S5 under pressure; then, they are shaped, dried, and fired to produce antique-style bricks.

2. The anti-slip and stain-resistant antique-style brick as described in claim 1, characterized in that: The chemical composition of the effect glaze includes: SiO2 40-49%, Al2O3 10-13%, Fe2O3 0-1%, TiO2 0-0.3%, CaO 2-8%, MgO 1-7%, K2O 2-6%, Na2O 1-5%, ZnO 2-4.5%, BaO 6-12%, ZrO2 5-7%, and loss on ignition 3-5.5%.

3. The anti-slip and stain-resistant antique-style brick as described in claim 1, characterized in that: The chemical composition of the blank includes: SiO2 66-69%, Al2O3 19.5-20.5%, Fe2O3 0.5-1.5%, TiO2 0.1-0.5%, CaO 0.3-1%, MgO 0.3-1%, K2O 2.5-3.5%, Na2O 1.5-2.5%, and loss on ignition 1-5%.

4. The anti-slip and stain-resistant antique-style brick as described in claim 1, characterized in that, In step S1, the specific steps are as follows: take the raw material of the billet and 1.5-2.5% of the billet auxiliary material by weight, add water and mix, ball mill, pass through a 240-260 mesh sieve to form a billet slurry with a sieve residue weight percentage of 0.8-1.2% and a moisture content of 35-38%, remove iron, sieve, spray dry, press into shape, dry, and obtain the billet; the billet auxiliary material is sodium tripolyphosphate and / or sodium metasilicate pentahydrate.

5. The anti-slip and stain-resistant antique-style brick as described in claim 1, characterized in that, In step S2, the preparation method of the anti-slip glaze is as follows: take the raw materials of the anti-slip glaze layer in the formula amount, add water and mix, ball mill, pass through a 320-330 mesh sieve to form an anti-slip glaze slurry with a sieve residue mass percentage of 0.3-0.5% and a water content of 31-37%, remove iron, and sieve to obtain the anti-slip glaze.

6. The anti-slip and stain-resistant antique-style brick as described in claim 1, characterized in that, In step S6, the firing temperature is 1235–1300℃ and the firing time is 66–100 min.

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