A concavo-convex texture ceramic tile with uniform color and a method for manufacturing the same

Abstract

The application discloses a preparation method of concave-convex texture ceramic tiles with uniform color and luster, and comprises the following steps: A, blank is pressed into a blank body by roller forming, and the blank body layer is obtained after first drying; B, printing ink of a mold is printed according to a preset pattern, digital face glaze is sprayed, and the concave-convex texture layer is formed after second drying; C, color ink is printed according to the preset pattern, and the inkjet printing layer is formed; D, digital protection glaze is sprayed, and the protection glaze layer is formed after third drying and fourth drying; E, kiln firing is performed, and the concave-convex texture ceramic tiles with uniform color and luster are obtained after polishing. The preparation method of the concave-convex texture ceramic tiles with uniform color and luster is simple in steps and high in operability, and under the premise of solving the black edge problem and ensuring the uniform color and luster of the ceramic tiles, the concave-convex texture effect with clear texture, high consistency and high fidelity is obtained on the surface of the ceramic tiles.

Description

Technical Field

[0001] This invention relates to the field of building ceramics technology, and in particular to a textured ceramic tile with uniform color and a method for its preparation. Background Technology

[0002] Tiles are a type of building material made from refractory metal oxides and semi-metal oxides through processes such as grinding, mixing, pressing, glazing, and sintering. As a building decoration material, they can not only be used to decorate buildings, making them beautiful and vibrant, but also to insulate the building surface from external environmental erosion, making the building more durable.

[0003] In the past two years, with the popularity of large slab and slab ceramic products, and the increasing application of ceramic products on walls, tabletops and countertops, consumers have put forward higher demands for building ceramic products. They not only pursue personalized pattern decoration design and excellent physical and chemical properties of ceramic products, but also have higher requirements for the surface texture and touch of ceramic products. Against this background, ceramic tiles with concave and convex texture effects have emerged.

[0004] In existing technologies, ceramic tiles with textured effects generally utilize oil-based mold ink to spread water-based glaze on the surface of the ceramic body, followed by printing colored ink to create colored textures. However, because the temperature of the ceramic body at the edges is lower than that in the center during the rolling process, the mold ink printed in the center of the ceramic body dries faster, while the mold ink printed at the edges dries slower. When the same amount of mold ink is printed on the entire surface of the ceramic body, the amount of mold ink accumulated at the edges of the ceramic body is greater than that in the center. When using the repulsive force between the oil-based mold ink and the water-based digital glaze to achieve the textured effect, the texture formed in the center is shallow, while the texture formed at the edges is deep. It is also easy to expose the edges of the ceramic body directly. Since the surface color of the ceramic body is generally dark, even if colored ink is applied subsequently, black edges are likely to appear on the surface of the ceramic tile. Summary of the Invention

[0005] One of the objectives of this invention is to propose a method for preparing textured ceramic tiles with uniform color. The method is simple and easy to operate. While solving the problem of black edges and ensuring the uniformity of color of the tiles, it enables the surface of the tiles to obtain a textured effect with clear texture, high consistency and high realism, thereby overcoming the shortcomings of the prior art.

[0006] The second objective of this invention is to provide a type of tile prepared by the above-mentioned method for preparing a uniformly colored textured tile. This tile has an excellent textured surface with uniform color, as well as good hardness, gloss and stain resistance, thus making the tile both decorative and practical.

[0007] To achieve this objective, the present invention adopts the following technical solution:

[0008] A method for preparing a textured ceramic tile with uniform color includes the following steps:

[0009] A. The billet is rolled into a blank body by roll forming, and the blank body layer is obtained after the first drying.

[0010] B. Print mold ink according to the preset pattern, spray digital surface glaze, and after a second drying, form a textured layer; wherein, the amount of mold ink printed decreases from the middle of the blank layer to the edge;

[0011] C. Print colored ink according to a preset pattern to form an inkjet printing layer; wherein, the colored ink includes white ink, and the amount of white ink printed increases sequentially from the middle of the blank layer to the edge;

[0012] D. Spraying digital protective glaze, followed by a third and fourth drying process, forms a protective glaze layer; wherein the temperature of the third drying is higher than the temperature of the fourth drying, and the drying time of the third drying is longer than the drying time of the fourth drying.

[0013] E. After firing in the kiln and polishing, a uniformly colored, textured ceramic tile is obtained.

[0014] Furthermore, in step B, the printing amount of the mold ink in the middle of the blank layer is 15-30 g / m. 2 Furthermore, the maximum reduction in the printing volume of the mold ink is 8 g / m³. 2 .

[0015] Furthermore, in step C, the amount of white ink printed in the middle of the blank layer is 6-10 g / m². 2 The specific gravity is 1.19–1.22, and the maximum increase in printing volume of the white ink is 4 g / m³. 2 .

[0016] Furthermore, in step C, the colored ink also includes non-white ink, and the printing amount of the non-white ink is 6-10 g / m³. 2 Its specific gravity is 1.19 to 1.22.

[0017] Furthermore, in step B, the printing temperature of the mold ink is 55–65°C.

[0018] Furthermore, it also includes step F, which precedes step B;

[0019] The specific steps of step F are as follows: apply a base glaze to the body layer to form a base glaze layer;

[0020] The amount of the base glaze applied is 250–600 g / m³. 2 .

[0021] Furthermore, the formula of the base glaze is the same as that of the digital surface glaze; and according to the mass parts, the digital surface glaze includes the following raw materials: 15-25 parts of potassium feldspar, 25-35 parts of sodium feldspar, 6-10 parts of washed kaolin, 5-9 parts of calcined alumina, 3-6 parts of calcined talc, 5-8 parts of dolomite, 8-12 parts of barium carbonate, 5-9 parts of quartz, 1-3 parts of zinc oxide, and 15-20 parts of zirconium silicate.

[0022] Further, in step C, the specific gravity of the digital glaze is 1.50–1.55, and the spraying amount of the digital glaze is 530–612 g / m³. 2 .

[0023] Furthermore, in step A, the drying temperature for the first drying is 80–100°C, and the drying time is 30–60 min.

[0024] In step B, the drying temperature for the second drying is 80-100℃, and the drying time is 2-4 minutes.

[0025] In step D, the drying temperature for the third drying is 100-120℃ and the drying time is 2-4 min; the drying temperature for the fourth drying is 80-100℃ and the drying time is 1-3 min.

[0026] A textured ceramic tile with uniform color is prepared by the above-described method for preparing textured ceramic tiles with uniform color.

[0027] The technical solutions provided in this application embodiment may include the following beneficial effects:

[0028] 1. In this technical solution, the printing amount of mold ink is limited to decrease from the middle of the body layer to the edge. That is, by differentiating the printing amount of mold ink in the middle of the brick body from the printing amount of mold ink at the edge, it is ensured that the amount of mold ink accumulation in the middle is basically the same as that at the edge. This ensures that the depth of the texture formed after the water-based digital glaze is physically dispersed by the mold ink with textured pattern is consistent. It avoids the texture being too deep at the edge, which can easily expose the edge of the body layer and cause black edges on the tile surface. This helps to ensure the uniformity of the tile color.

[0029] 2. By limiting the printing amount of white ink in the color ink to increase sequentially from the middle to the edge of the brick body layer, that is, by differentiating the printing amount of white ink in the middle of the brick body layer from the printing amount of white ink at the edge, the color of the color ink at the edge of the brick body layer is lighter than that in the middle of the brick body layer. This, in conjunction with the differentiated printing amount of the mold ink, ensures the uniformity of color on the surface of the dried tile.

[0030] 3. This technical solution differentiates the printing amount of mold ink in the middle of the brick blank layer from that at the edge, which also helps to obtain a clear, consistent and realistic textured effect on the surface of the tile. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the region division on the surface of the body layer in Example 1 of the preparation method of a uniformly colored textured ceramic tile according to the present invention. Detailed Implementation

[0032] This technical solution provides a method for preparing textured ceramic tiles with uniform color and raised surface, including the following steps:

[0033] A. The billet is rolled into a blank body by roll forming, and the blank body layer is obtained after the first drying.

[0034] B. Print mold ink according to the preset pattern, spray digital surface glaze, and after a second drying, form a textured layer; wherein, the amount of mold ink printed decreases from the middle of the blank layer to the edge;

[0035] C. Print colored ink according to a preset pattern to form an inkjet printing layer; wherein, the colored ink includes white ink, and the amount of white ink printed increases sequentially from the middle of the blank layer to the edge;

[0036] D. Spraying digital protective glaze, followed by a third and fourth drying process, forms a protective glaze layer; wherein the temperature of the third drying is higher than the temperature of the fourth drying, and the drying time of the third drying is longer than the drying time of the fourth drying.

[0037] E. After firing in the kiln and polishing, a uniformly colored, textured ceramic tile is obtained.

[0038] To address the technical problems of black edges and uneven color in existing textured ceramic tiles, this technical solution proposes a method for preparing textured ceramic tiles with uniform color. The method includes five steps: A (battery preparation), B (printing mold ink and spraying digital glaze), C (printing ink), D (spraying digital protective glaze), and E (firing in a kiln). By progressively decreasing the amount of mold ink printed from the center to the edge of the tile body, combined with progressively increasing the amount of white ink printed from the center to the edge, the black edge problem is solved, ensuring uniform color. Simultaneously, the tile surface achieves a clear, consistent, and highly realistic textured effect to meet usage requirements. It should be noted that the tile body in this solution is made from conventional ceramic blanks that have been pressed and dried; further description of the ceramic blanks is not provided here.

[0039] Specifically, because the temperature of the blank at the edge is lower than that in the middle during the blanking process, when the same amount of mold ink is printed on the entire surface of the blank, the uneven texture formed in the middle is shallow, while the uneven texture formed at the edge is deep. It is also easy to expose the edge of the blank layer directly. Since the color of the blank layer is generally dark, even if colored ink is applied later, black edges are likely to appear on the edge of the tile surface.

[0040] In this technical solution, the printing amount of mold ink is limited to decrease sequentially from the middle of the body layer to the edge. That is, by differentiating the printing amount of mold ink in the middle of the brick body from the printing amount of mold ink at the edge, it is ensured that the amount of mold ink accumulation in the middle is basically the same as that at the edge. This ensures that the depth of the texture formed after the water-based digital glaze is physically dispersed by the mold ink with textured pattern is consistent. It avoids the texture being too deep at the edge, which can easily expose the edge of the body layer and cause black edges on the tile surface. This helps to ensure the uniformity of the tile color.

[0041] While differentiating the printing volume of the mold ink can prevent direct exposure of the edges of the tile body and ensure color consistency, the color uniformity of the tile is also closely related to the color ink itself. Relying solely on differentiating the printing volume of the mold ink is insufficient to guarantee color uniformity. Therefore, this technical solution limits the printing volume of white ink in the color ink to increase sequentially from the center to the edge of the tile body. This differentiates the printing volume of white ink in the center of the tile body from that at the edges, resulting in a lighter color at the edges compared to the center. This, combined with the differentiating printing volume of the mold ink, ensures color uniformity on the dried tile surface.

[0042] Furthermore, when the textured surface in the center of the tile is shallower than that on the edges, it not only easily leads to black edges but also results in inconsistent texture effects. Additionally, the shallower texture in the center can cause a loss of detail, affecting the clarity and realism of the textured surface. Therefore, this technical solution differentiates the printing volume of the mold ink in the center of the tile body from that at the edges, which also helps to achieve a clear, consistent, and highly realistic textured surface on the tile.

[0043] More specifically, the uniformly colored textured ceramic tile produced by this technical solution is prepared through five steps: pressing the raw material into a blank using roller pressing, and performing a first drying process to facilitate the shaping of the bisque and subsequent processes. It should be noted that the blank layer in this solution is made from conventional ceramic raw materials that have been pressed and dried, and the ceramic raw materials will not be further described here.

[0044] Secondly, mold ink is printed according to a preset pattern, followed by spraying digital glaze. After a second drying, a textured layer is formed. The mold ink with the textured pattern physically repels the subsequently sprayed water-based digital glaze, thus creating the mold texture on the digital glaze layer. Then, the ceramic body with the digital glaze is dried a second time to reduce the fluidity of the digital glaze, further ensuring the tile has a strong three-dimensional mold texture. Furthermore, the second drying is performed after spraying the digital glaze, rather than after printing the mold ink and before spraying the digital glaze, to avoid the digital glaze affecting the color development of the color ink during printing, which could lead to yellowing of the tile surface and a blurred pattern. It should be noted that technicians can determine the preset pattern of the mold ink according to the actual production needs of the tile. The mold ink in this technical solution is a commonly used mold ink in the field for repelling water-based glaze to form a textured surface.

[0045] Furthermore, colored ink is printed according to a preset pattern to form an inkjet printing layer; this solution utilizes colored ink to superimpose pattern textures on the mold texture formed by the mold ink, which helps to enrich the texture effect of the tiles.

[0046] It should be noted that the preset patterns of the mold ink and the preset patterns of the color ink in this technical solution can be one-to-one or they can be mutually uncorresponding. Technicians can determine the preset patterns of the color inks according to the actual production needs of the tiles. The color inks in this technical solution are commonly used in the field for forming pattern textures. Since the pattern printing of the inkjet printer is controlled by software programs, the patterns of the mold ink and color inks can be changed by modifying the software program, which is convenient, quick, and helps to reduce production costs.

[0047] Secondly, a digital protective glaze is sprayed, followed by a third and fourth drying process to form a protective glaze that protects the tile and ensures its hardness. However, due to the large ink volume of the protective glaze, if the third drying is performed immediately after printing the ink, the fourth drying temperature will be too high, potentially causing the tile to crack and affecting the yield. Furthermore, since the digital protective glaze is generally applied in large quantities, this technical solution limits the third drying temperature to be higher than the fourth drying temperature, and the third drying time to be longer than the fourth drying time. This ensures the digital protective glaze dries completely, preventing peeling due to incomplete drying and other adverse effects. Additionally, the fourth drying after the third helps control the moisture content of the ceramic body before firing to below 0.8%, preventing excessive moisture content during firing and thus preventing cracking and affecting the yield. It should be noted that the digital protective glaze used in this solution is a commonly used protective glaze in the ceramic industry; further description of the digital protective glaze is not provided here.

[0048] Finally, the tiles are fired in a kiln and polished to obtain a uniformly colored, textured surface. This process also ensures the surface of the tiles is smooth, guaranteeing their stain resistance and gloss. It should be noted that the polishing step can be any of the following: full polishing, partial polishing, or sweep polishing; no specific method is specified here.

[0049] Preferably, in step D, the digital protective glaze is passed through a 325-mesh sieve, with a residue of 0.3-0.6%, the specific gravity of the digital protective glaze is 1.65-1.85, the flow rate is 25-38 s, and the spraying amount of the digital protective glaze is 300-600 g / m³. 2 .

[0050] In a preferred embodiment of this technical solution, the digital protective glaze is passed through a 325-mesh sieve, with a residue of 0.3-0.6%, which facilitates the formation of a dense glaze layer, avoids the generation of bubbles and pinholes in the glaze layer, and ensures a good glaze surface effect. Furthermore, controlling the specific gravity and flow rate of the digital protective glaze allows for the deposition of an ideal thickness of glaze layer on top of the tile while ensuring stable glazing quality, thereby ensuring the tile's hardness.

[0051] Furthermore, this scheme limits the amount of digital protective glaze applied to be 300–600 g / m². 2 This helps to ensure the hardness and wear resistance of the fired ceramic tiles, so that the surface of the tiles, whether fully polished or polished by sweeping / semi-polishing, can still meet the production requirements in terms of hardness and wear resistance.

[0052] To further explain, in step B, the printing amount of the mold ink in the middle of the blank layer is 15-30 g / m. 2Furthermore, the maximum reduction in the printing volume of the mold ink is 8 g / m³. 2 .

[0053] The less ink is sprayed from the mold ink, the shallower the mold texture formed by the digital glaze layer, and vice versa. To avoid mutual interference between textures, the ceramic tile body needs to undergo multiple drying processes during the tile preparation process. However, because the greater the ink spray volume of the mold ink, the higher the temperature required for drying, the more prone the edges of the ceramic tile body are to warping. Warping of the ceramic tile body affects both the tile laying process and the flatness of the finished slab, and also makes its surface prone to cracking. Therefore, in a preferred embodiment of this technical solution, in order to simultaneously consider the mold texture effect and flatness, this solution limits the ink spray volume of the mold ink to 15-30 g / m³. 2 .

[0054] Furthermore, if the reduction in mold ink amount is too large, the printing amount of mold ink at the edges will be too small, affecting the effect of the raised texture at the edges; if the reduction in mold ink amount is too small, the printing amount of mold ink at the edges will be too large, resulting in a deep raised texture at the edges, and it is also easy to expose the edges of the body layer, which can easily affect the color uniformity of the tile. Therefore, in a preferred embodiment of this technical solution, the maximum reduction in the printing amount of mold ink is limited to 8g / m³. 2 (That is, when the printing amount of mold ink in the middle of the blank layer is 15g / m) 2 At that time, the printing amount of mold ink at the edge of the blank layer was 7g / m. 2 When the printing amount of mold ink in the middle of the blank layer is 30g / m 2 At that time, the printing amount of mold ink at the edge of the blank layer was 22g / m. 2 Following this example, the printing amount of mold ink at the edge of the blank layer should be in the range of 7–22 g / m. 2 This ensures the uniformity of the tile's color and the effect of its textured surface.

[0055] To further clarify, in step C, the amount of white ink printed in the middle of the blank layer is 6-10 g / m². 2 The specific gravity is 1.19–1.22, and the maximum increase in printing volume of the white ink is 4 g / m³. 2 .

[0056] In a preferred embodiment of this technical solution, to ensure that the black edge problem can be solved and the color uniformity of the tile can be guaranteed, the preferred printing amount of white ink in the middle of the body layer is 6-10 g / m². 2 .

[0057] Furthermore, the specific gravity of the white ink is optimized. If the specific gravity of the white ink is low, the white ink will have good fluidity after spraying, which is not conducive to solving the black edge problem and affects the color uniformity of the tile. If the specific gravity of the white ink is high, the white ink will have poor fluidity, which will also affect the color uniformity of the tile.

[0058] Furthermore, if too much white ink is added, the edges of the tile will tend to be lighter in color, while the center will be darker; conversely, if too little white ink is added, the edges will tend to be darker, while the center will be lighter. Therefore, in a preferred embodiment of this technical solution, the maximum increase in the amount of white ink printed is limited to 4 g / m². 2 (That is, when the amount of white ink printed in the middle of the blank layer is 6g / m) 2 At that time, the amount of white ink printed at the edge of the preform layer was 10 g / m. 2 When the amount of white ink printed in the middle of the blank layer is 10 g / m 2 At that time, the printing amount of mold ink at the edge of the blank layer was 14 g / m. 2 Following this example, the printing amount of white ink at the edge of the blank layer should be in the range of 10–14 g / m². 2 This ensures the uniformity of the tile's color after drying.

[0059] To further clarify, in step C, the colored ink also includes non-white ink, and the printing amount of the non-white ink is 6-10 g / m³. 2 Its specific gravity is 1.19 to 1.22.

[0060] In a preferred embodiment of this technical solution, by limiting the printing volume and specific gravity of non-white ink, and coordinating them with the printing volume and specific gravity of white ink, it is beneficial to solve the black edge problem, ensure the color uniformity of the tiles, and at the same time avoid excessive ink volume and the ink supply system being unable to keep up with the ink printing demand.

[0061] To further explain, in step B, the printing temperature of the mold ink is 55–65°C.

[0062] The printing temperature of existing printing mold inks is controlled at 45-55℃. This technical solution controls the printing temperature of the mold ink at 55-65℃, which is higher than the printing temperature of existing mold inks. This is beneficial to improve the drying speed of the mold ink, thereby improving the drying speed of the digital glaze. It also reduces the black edge phenomenon caused by the inconsistent drying speed between the edge and the center of the body layer, which helps to solve the black edge problem and improve the color uniformity of the tiles.

[0063] To further explain, it also includes step F, which precedes step B;

[0064] The specific steps of step F are as follows: apply a base glaze to the body layer to form a base glaze layer;

[0065] The amount of the base glaze applied is 250–600 g / m³. 2 .

[0066] In a preferred embodiment of this technical solution, a base glaze layer made of base glaze can also be provided on the top of the body layer. The base glaze layer can cover the body layer, on the one hand, preventing the body layer from being exposed and black edges due to the deep texture at the edges after the subsequent sprayed water-based digital glaze is physically displaced by the mold ink with textured pattern; on the other hand, it also avoids the body layer from affecting the pattern texture of the color ink, which is conducive to further improving the color effect of the pattern texture.

[0067] Furthermore, the amount of base glaze applied is 250–600 g / m². 2 This further ensures the coverage of the base glaze layer on the body layer, while also ensuring the flatness of the base glaze layer, which facilitates the printing of texture ink, thereby ensuring the three-dimensional texture effect of the texture layer.

[0068] To further clarify, the formula of the base glaze is the same as that of the digital surface glaze; and calculated by mass parts, the digital surface glaze includes the following raw materials: 15-25 parts potassium feldspar, 25-35 parts sodium feldspar, 6-10 parts washed kaolin, 5-9 parts calcined alumina, 3-6 parts calcined talc, 5-8 parts dolomite, 8-12 parts barium carbonate, 5-9 parts quartz, 1-3 parts zinc oxide, and 15-20 parts zirconium silicate.

[0069] In a preferred embodiment of this technical solution, the raw materials for the digital glaze include potassium feldspar, sodium feldspar, washed kaolin, calcined alumina, calcined talc, dolomite, barium carbonate, quartz, zinc oxide, and zirconium silicate. Potassium feldspar promotes the development of red color in the ink and increases the coefficient of thermal expansion of the digital glaze; sodium feldspar promotes the development of yellow color in the ink and also increases the coefficient of thermal expansion of the digital glaze; washed kaolin effectively improves the suspension of the glaze slurry and the firing temperature of the glaze, thereby increasing the high-temperature viscosity of the digital glaze; the introduction of calcined alumina helps to increase the firing temperature of the digital glaze formula, and also improves the whiteness and high-temperature viscosity of the digital glaze; the introduction of calcined talc is used to adjust the coefficient of thermal expansion. The firing process of the digital glaze; the addition of dolomite can lower the initial melting point and coefficient of expansion of the digital glaze; the addition of barium carbonate can react with other raw materials of the glaze at high temperature to form a solid solution, filling the pores on the porcelain surface, thereby improving the smoothness and hardness of the porcelain surface; the addition of quartz is beneficial to promoting color development, while also increasing the firing temperature and coefficient of expansion of the glaze, and increasing the high-temperature viscosity of the digital glaze; zinc oxide mainly acts as a flux, and can also promote the red color development in the color ink; zirconium silicate mainly acts as a whitening agent, and can also effectively reduce the coefficient of expansion of the digital glaze and increase the high-temperature viscosity of the digital glaze. The amount of zirconium silicate used in the scheme is effectively reduced, which can also reduce the production cost of the glaze.

[0070] This solution improves the formulation of the digital glaze, effectively increasing its high-temperature viscosity. This maximizes the preservation of the mold texture effect during glazing, thereby enhancing the three-dimensional effect of the mold texture. Furthermore, the increased high-temperature viscosity of the glaze improves the adhesion between the glaze and the tile body. Adjusting the coefficient of thermal expansion of the digital glaze also ensures tile stability and prevents tile warping. Simultaneously, limiting the addition of zirconium silicate to 15-20 parts ensures that the glaze layer, when used as a base glaze, effectively covers the tile body. This helps prevent the formation of uneven textured layers, where the uneven texture at the edges is deeper than the whiteness of the base glaze, leading to exposure of the tile body and affecting the color uniformity of the tile surface.

[0071] To further clarify, in step C, the specific gravity of the digital glaze is 1.50–1.55, and the spraying amount of the digital glaze is 530–612 g / m³. 2 .

[0072] To ensure that the mold texture formed on the digital glaze layer in this technical solution has a deep three-dimensional effect, the preferred glaze application amount is 555-612 g / m². 2In addition, this solution also optimizes the specific gravity of the digital glaze. If the specific gravity of the digital glaze is low, the fluidity of the sprayed digital glaze will be good, which is not conducive to forming a stable and clear mold texture. If the specific gravity of the digital glaze is high, the atomization effect of the digital glaze will be poor, which will easily lead to a rough glaze surface.

[0073] To further explain, in step A, the drying temperature for the first drying is 80-100℃, and the drying time is 30-60 minutes.

[0074] In step B, the drying temperature for the second drying is 80-100℃, and the drying time is 2-4 minutes.

[0075] In step D, the drying temperature for the third drying is 100-120℃ and the drying time is 2-4 min; the drying temperature for the fourth drying is 80-100℃ and the drying time is 1-3 min.

[0076] In a preferred embodiment of this technical solution, by optimizing the drying time and temperature of the blank layer, the blank layer is ensured to be completely dry, while defects such as blisters are avoided when printing mold ink. If the drying temperature is too high or the drying time is too long, it will not be very effective in reducing blisters; if the drying temperature is too low or the drying time is too short, it will increase the moisture content of the blank layer, reduce the strength of the blank layer, and affect the loss.

[0077] In a preferred embodiment of this technical solution, by limiting the drying temperature and time of the second drying, it is ensured that the moisture in the digital glaze is sufficiently dried, reducing the fluidity of the digital glaze and further ensuring the textured effect of the tile. At the same time, it avoids excessively high drying temperature and excessively long drying time, which could lead to cracking of the tile, thereby ensuring the quality of the product.

[0078] Furthermore, limiting the temperature and time for the three drying stages helps ensure the digital protective glaze dries completely, preventing peeling caused by incomplete drying and other adverse effects. Additionally, limiting the temperature and time for the fourth drying stage helps control the moisture content of the blank before firing to below 0.8%, preventing excessive moisture and subsequent cracking during firing, thus ensuring a higher product yield. It should be noted that the temperature for the third drying stage is higher than the temperature for the fourth, and the drying time for the third is longer than the time for the fourth.

[0079] A textured ceramic tile with uniform color is prepared by the above-described method for preparing textured ceramic tiles with uniform color.

[0080] This solution also proposes a textured tile with uniform color, which solves the problem of black edges on the tile and ensures uniform color while giving the tile surface a clear, consistent, and realistic textured effect. In addition, it has good hardness, gloss, and stain resistance, thus making the tile both decorative and practical, which is more conducive to meeting the needs of consumers.

[0081] The technical solution of the present invention will be further illustrated below through specific embodiments.

[0082] Example 1

[0083] A. The billet is rolled into a blank body by roll forming, and the blank body layer is obtained after the first drying; the drying temperature of the first drying is 100℃ and the drying time is 30min;

[0084] B. Print mold ink at 55℃ according to the preset pattern, with a spraying specific gravity of 1.50 and a spraying amount of 612g / m³. 2 The digital glaze, after a second drying process, forms a textured layer, including, for example... Figure 1 As shown, the surface of the preform layer is divided into four regions from the inside out: region 1, region 2, region 3, and region 4. The printing amount of the mold ink in region 1 of the preform layer is 15 g / m³. 2 The printing amount of mold ink in the second region 2 of the preform layer is 12 g / m². 2 The printing amount of mold ink in the third region 3 of the preform layer is 9 g / m³. 2 The printing amount of mold ink in the fourth region 4 of the preform layer is 7 g / m². 2 According to the mass fraction, the digital glaze consists of 15 parts potassium feldspar, 35 parts sodium feldspar, 6 parts washed kaolin, 5 parts calcined alumina, 3 parts calcined talc, 5 parts dolomite, 10 parts barium carbonate, 5 parts quartz, 2 parts zinc oxide, and 15 parts zirconium silicate; the second drying temperature is 80℃ and the drying time is 4min.

[0085] C. Print colored ink according to the preset pattern to form an inkjet printing layer. The colored ink includes white ink and non-white ink. The specific gravity of the non-white ink is 1.22, and the printing amount is 6g / m³. 2 The specific gravity of the white ink is 1.22, and the printing amount of white ink in the first region 1 of the blank layer is 6 g / m². 2 The printing amount of white ink in the second region 2 of the preform layer is 7.5 g / m². 2 The printing amount of white ink in the third region 3 of the preform layer is 8.5 g / m³. 2 The printing amount of white ink in the fourth region 4 of the preform layer is 10 g / m². 2 ;

[0086] D. The coating is sprayed through a 325-mesh sieve, with a residue of 0.4%, a specific gravity of 1.75, a flow rate of 30 seconds, and a glaze application rate of 600 g / m³. 2 The digital protective glaze undergoes a third and fourth drying process to form a protective glaze layer. The third drying process is carried out at a temperature of 100℃ for 4 minutes, and the fourth drying process is carried out at a temperature of 80℃ for 3 minutes.

[0087] E. Firing at 1300℃ for 120 minutes and polishing to obtain a uniformly colored textured ceramic tile.

[0088] Example 2

[0089] A. The billet is rolled into a blank body by roller pressing, and the blank body layer is obtained after the first drying; the drying temperature of the first drying is 80℃ and the drying time is 60min;

[0090] B. Print mold ink at 60℃ according to the preset pattern, with a spraying specific gravity of 1.55 and a spraying amount of 530g / m³. 2 The digital glaze, after a second drying process, forms a textured layer. The surface of the blank layer is divided into four regions from the inside out: region 1, region 2, region 3, and region 4. The printing amount of the mold ink in region 1 of the blank layer is 30 g / m². 2 The printing amount of mold ink in the second region 2 of the preform layer is 28 g / m². 2 The printing amount of mold ink in the third region 3 of the preform layer is 26 g / m³. 2 The printing amount of mold ink in the fourth region 4 of the preform layer is 24 g / m². 2 According to the mass fractions, the digital glaze consists of 25 parts potassium feldspar, 25 parts sodium feldspar, 10 parts washed kaolin, 5 parts calcined alumina, 3 parts calcined talc, 5 parts dolomite, 8 parts barium carbonate, 5 parts quartz, 1 part zinc oxide, and 15 parts zirconium silicate; the second drying temperature is 100℃ and the drying time is 2 minutes.

[0091] C. Print the ink according to the preset pattern to form an inkjet printing layer. The ink includes white ink and non-white ink. The specific gravity of the non-white ink is 1.19, and the printing amount is 10g / m³. 2 The specific gravity of the white ink is 1.19, and the printing amount of white ink in the first region 1 of the blank layer is 10 g / m². 2 The amount of white ink printed in the second region 2 of the preform layer was 11 g / m². 2 The printing amount of white ink in the third region 3 of the preform layer is 12 g / m². 2 The printing amount of white ink in the fourth region 4 of the preform layer is 13 g / m². 2 ;

[0092] D. The coating is sprayed through a 325-mesh sieve, with a residue of 0.6%, a specific gravity of 1.85, a flow rate of 30 s, and a glaze application rate of 450 g / m³. 2 The digital protective glaze undergoes a third and fourth drying process to form a protective glaze layer. The third drying process is carried out at a temperature of 120℃ for 2 minutes, and the fourth drying process is carried out at a temperature of 100℃ for 1 minute.

[0093] E. Firing at 1400℃ for 90 minutes and polishing to obtain a uniformly colored textured ceramic tile.

[0094] Example 3

[0095] A. The billet is rolled into a blank body by roll forming, and the blank body layer is obtained after the first drying; the drying temperature of the first drying is 90℃ and the drying time is 45min;

[0096] F. Apply glaze to the blank layer at a rate of 250 g / m². 2 The base glaze forms a base glaze layer; according to the mass fraction, the base glaze includes 20 parts potassium feldspar, 30 parts sodium feldspar, 8 parts washed kaolin, 7 parts calcined alumina, 5 parts calcined talc, 6 parts dolomite, 10 parts barium carbonate, 7 parts quartz, 2 parts zinc oxide and 18 parts zirconium silicate.

[0097] B. Print the mold ink at 65℃ according to the preset pattern, with a spraying specific gravity of 1.53 and a spraying amount of 600g / m³. 2 The digital glaze, after a second drying process, forms a textured layer. The surface of the blank layer is divided into four regions from the inside out: region 1, region 2, region 3, and region 4. The printing amount of the mold ink in region 1 of the blank layer is 20 g / m². 2 The printing amount of mold ink in the second region 2 of the preform layer is 18.5 g / m². 2 The printing amount of mold ink in the third region 3 of the preform layer is 17 g / m³. 2 The printing amount of mold ink in the fourth region 4 of the preform layer is 16 g / m². 2 According to the mass fraction, the digital glaze consists of 20 parts potassium feldspar, 30 parts sodium feldspar, 8 parts washed kaolin, 7 parts calcined alumina, 5 parts calcined talc, 6 parts dolomite, 10 parts barium carbonate, 7 parts quartz, 2 parts zinc oxide, and 18 parts zirconium silicate; the second drying temperature is 90℃ and the drying time is 3 minutes.

[0098] C. Print colored inks according to the preset pattern to form an inkjet printing layer. The colored inks include white ink and non-white ink. The specific gravity of the non-white ink is 1.20, and the printing amount is 8g / m³. 2The specific gravity of the white ink is 1.20, and the printing amount of white ink in the first region 1 of the preform layer is 8 g / m². 2 The printing amount of white ink in the second region 2 of the preform layer was 8.8 g / m². 2 The white ink was printed in region 3 of the preform layer at a rate of 9.5 g / m³. 2 The printing amount of white ink in the fourth region 4 of the preform layer is 10 g / m². 2 ;

[0099] D. The coating is sprayed through a 325-mesh sieve, with a residue of 0.3%, a specific gravity of 1.65, a flow rate of 25 seconds, and a glaze application rate of 300 g / m³. 2 The digital protective glaze undergoes a third and fourth drying process to form a protective glaze layer. The third drying process is carried out at a temperature of 110℃ for 3 minutes, and the fourth drying process is carried out at a temperature of 90℃ for 2 minutes.

[0100] E. Firing at 1300℃ for 110 minutes and polishing to obtain a uniformly colored textured ceramic tile.

[0101] Comparative Example 1

[0102] The preparation methods and raw materials of Comparative Example 1 and Example 1 are the same. The difference is that in step B of Comparative Example 1, the printing amount of mold ink is the same on the entire surface of the blank, and the printing amount of mold ink is 20 g / m. 2 .

[0103] Comparative Example 2

[0104] The preparation methods and raw materials of Comparative Example 2 are the same as those of Example 1. The difference is that the amount of white ink printed on the entire surface of the blank is the same in Comparative Example 2, and the amount of white ink printed is 8 g / m². 2 .

[0105] Tiles were prepared using the preparation methods described in Examples 1-3 and Comparative Examples 1-2, respectively. The glaze effect of the tiles was observed with the naked eye, and the prepared tiles were subjected to conventional tests in the field of building ceramics, including hardness, gloss, and stain resistance. The results are shown in Table 1 below.

[0106] Table 1 Performance test results of ceramic tiles prepared by different methods

[0107]

[0108] As shown in Table 1, the method for preparing textured tiles with uniform color solves the problem of black edges and ensures uniform color. At the same time, it gives the tile surface a textured effect with clear texture, high consistency and high realism. In addition, it also has good hardness, gloss and stain resistance, so that the tile has both decorative and practical functions, which is more conducive to meeting the needs of consumers.

[0109] In Comparative Example 1, because the printing of the mold ink on the entire surface of the ceramic body is the same, the amount of mold ink accumulated at the edge of the ceramic body layer is greater than that in the middle. When using the repulsive force between the oil-based mold ink and the water-based digital glaze to achieve the textured effect, the texture formed in the middle is shallow, while the texture formed at the edge is deep. It is also easy to expose the edge of the ceramic body layer directly. Since the color of the ceramic body layer is generally dark, even if colored ink is applied later, black edges are likely to appear on the edge of the tile surface. At the same time, because the texture in the middle of the tile is shallow, it is easy to lose details, affecting the clarity and realism of the texture of the tile.

[0110] In Comparative Example 2, due to the consistent printing volume of white ink, the color of the raised texture at the edge of the tile was slightly darker than that in the center of the tile, and the tile still exhibited a black edge phenomenon.

[0111] The technical principles of the present invention have been described above with reference to specific embodiments. These descriptions are merely for explaining the principles of the invention and should not be construed as limiting the scope of protection of the invention in any way. Based on this explanation, those skilled in the art can readily conceive of other specific embodiments of the invention without inventive effort, and these embodiments will all fall within the scope of protection of the present invention.

Claims

1. A method for producing a concavo-convex texture ceramic tile having uniform color, characterized in that, The method comprises the following steps: A. pressing the blank into a green body by roller forming, and performing first drying to obtain a green body layer; B. printing mold ink according to a preset pattern, spraying digital face glaze, and performing second drying to form a concave-convex texture layer; wherein the printing amount of the mold ink decreases from the middle part to the edge of the green body layer; C. printing color ink according to a preset pattern to form an inkjet printing layer; wherein the color ink comprises white ink, and the printing amount of the white ink increases from the middle part to the edge of the green body layer; D. spraying digital protection glaze, and performing third drying and fourth drying to form a protection glaze layer; wherein the temperature of the third drying is higher than that of the fourth drying, and the time of the third drying is longer than that of the fourth drying; E. entering a kiln chamber for firing, and polishing to obtain a concave-convex texture ceramic tile with uniform color and luster.

2. A method of producing a concavo-convex texture ceramic tile having uniform color according to claim 1, characterized in that, In step B, the printing amount of the mold ink in the middle part of the green body layer is 15 to 30 g / m 2 , and the maximum reduction of the printing amount of the mold ink is 8 g / m 2 .

3. A method of producing a concavo-convex texture ceramic tile having uniform color according to claim 2, characterized in that, In Step C, the printing amount of the white ink in the middle of the body layer is 6 to 10 g / m 2 , the specific gravity is 1.19 to 1.22, and the maximum increase in the printing amount of the white ink is 4 g / m 2 .

4. A method of producing a concavo-convex texture ceramic tile having uniform color according to claim 3, characterized in that, In Step C, the color ink further includes a non-white ink, and the print amount of the non-white ink is 6 to 10 g / m 2 The specific gravity is 1.19 to 1.

22.

5. A method of producing a concavo-convex texture ceramic tile having uniform color according to claim 3, wherein In step B, the printing temperature of the mold ink is 55-65℃.

6. A method of producing a concavo-convex texture ceramic tile having uniform color according to claim 1, wherein The method further comprises step F, and step F is located before step B; Step F specifically comprises the following step: applying a base glaze on the green body layer to form a base glaze layer. The application amount of the bottom glaze is 250-600 g / m 2 .

7. A method of producing a concavo-convex texture ceramic tile having uniform color according to claim 6, characterized in that, The formula of the base glaze is the same as that of the digital face glaze; and the digital face glaze comprises the following raw materials according to mass fraction: 15-25 parts of potassium feldspar, 25-35 parts of sodium feldspar, 6-10 parts of water-washed kaolin, 5-9 parts of calcined alumina, 3-6 parts of calcined talc, 5-8 parts of dolomite, 8-12 parts of barium carbonate, 5-9 parts of quartz, 1-3 parts of zinc oxide, and 15-20 parts of zirconium silicate.

8. A method of producing a concavo-convex texture ceramic tile having uniform color according to claim 1, wherein In Step C, the specific gravity of the digital face enamel is 1.50-1.55, and the spray enamel amount of the digital face enamel is 530-612 g / m 2 .

9. A method of producing a concavo-convex texture ceramic tile having uniform color according to claim 1, wherein In step A, the drying temperature of the first drying is 80-100℃, and the drying time is 30-60 min; In step B, the drying temperature of the second drying is 80-100℃, and the drying time is 2-4 min; In step D, the drying temperature of the third drying is 100-120℃, and the drying time is 2-4 min; and the drying temperature of the fourth drying is 80-100℃, and the drying time is 1-3 min.

10. A concavo-convex textured ceramic tile having uniform color, characterized in that, The concave-convex texture ceramic tile with uniform color and luster is prepared by the method of any one of claims 1-9.

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