A stain resistant, soft-finish brick and method of making same

Abstract

The application discloses a kind of preparation methods of soft polishing brick resistant to dirt, comprising the following steps: A. preparation blank and dry;B. face glaze is applied, and face glaze layer is formed;C. according to preset pattern printing color ink, and form inkjet printing layer;D. glaze is applied, and glaze layer is formed;E. after drying, into kiln firing, after polishing treatment, obtain polishing semi-finished product;F. wear-resistant dirt-resistant coating is added dropwise to the surface of polishing semi-finished product, and dirt-resistant film layer is formed after polishing using super clean bright machine, obtain soft polishing brick resistant to dirt;Wherein, the wear-resistant dirt-resistant coating includes binder and curing agent, the binder includes hydrogenated silicone oil, silicone resin, 903 glue and solvent;The raw material of the 903 glue includes heavy calcium carbonate and 707 water-soluble resin;The curing agent is silane coupling agent.The preparation method of soft polishing brick resistant to dirt proposed in the application is simple, and operability is strong, to ensure that the soft polishing brick obtained simultaneously has soft light and dirt-resistant durability.

Description

Technical Field

[0001] This invention relates to the field of building ceramics technology, and in particular to a stain-resistant flexible polished brick and its preparation method. Background Technology

[0002] With the continuous improvement of living standards and aesthetic appreciation, consumers have increasingly higher requirements for the material, pattern, and translucency of bricks used in building decoration. Currently, glazed tiles are the main type on the market. Glazed tiles are generally made by printing on the tile blank or applying a base glaze and then printing on the blank, followed by applying a layer of glaze, firing in a kiln, and then polishing the glaze layer to obtain glazed tile products. They have high gloss and good decorative effect, but the glaze layer generally also has disadvantages such as poor translucency, more pores, and more water ripples.

[0003] To address the shortcomings of glazed tiles, the industry has developed soft-polished tiles. Based on existing tile manufacturing processes, soft-polished tiles achieve a softer, more luminous finish by adjusting the glaze formula and polishing technique, along with mold design and overall aesthetics. This avoids the light pollution issues caused by the high gloss (up to 90°) of glazed tiles, creating a visually comfortable and artistically sophisticated warm space that better meets people's needs for softer aesthetics. Furthermore, soft-polished tiles have a smooth surface without water ripples, are durable, wear-resistant, and scratch-resistant, with clearer textures and more three-dimensional layers, meeting actual market demands.

[0004] Currently, soft-polished tiles are generally polished with abrasive blocks after glazing to obtain a soft gloss. However, since the finer the abrasive block, the higher the gloss, in order to obtain a soft gloss of less than 50°, the polishing process can only use relatively coarse abrasive blocks. Coarser abrasive blocks will cause pores and polishing scratches on the surface of the polished soft-polished tiles, which will damage their flatness and density, and reduce their stain resistance.

[0005] To ensure the stain resistance of soft-polished bricks, existing technologies generally employ a stain-resistant film layer applied to the surface of the polished semi-finished product after polishing to fill the pores and remove polishing scratches. Specifically: (1) Applying a super-cleaning brightener to the surface of the polished semi-finished product after polishing to fill the pores and remove polishing scratches, thereby improving the stain resistance of the soft-polished bricks. However, due to the high gloss of the super-cleaning brightener, the gloss of the soft-polished bricks will be significantly increased to over 80°, losing the soft-light effect. (2) Applying small-molecule silicone oils such as dimethylsiloxane (DMSO) and trimethylsiloxane (TMSO) to the surface of the polished semi-finished product, utilizing the penetrability of the small-molecule silicone oil to fill the pores and remove polishing scratches, and forming a smooth and delicate stain-resistant film layer that adheres to the surface of the polished semi-finished product, thereby improving the stain resistance of the soft-polished bricks. However, since the stain-resistant film formed by small molecule silicone oil only adheres to the surface of the polished semi-finished product through physical action, the stain-resistant film is easily worn away during the daily use of soft-polished tiles, resulting in the stain resistance of soft-polished tiles not lasting.

[0006] In summary, existing technologies cannot simultaneously achieve both a soft finish and durable stain resistance in polished bricks to meet usage requirements. Summary of the Invention

[0007] The primary objective of this invention is to provide a method for preparing stain-resistant soft-polished bricks. The method is simple, easy to operate, and ensures that the resulting soft-polished bricks possess both a soft sheen and durable stain resistance.

[0008] The second objective of this invention is to provide a method for preparing stain-resistant soft-polished bricks, which produces soft-polished bricks with a gloss of 13-35°, a soft luster, and a stain resistance rating of 5.

[0009] To achieve this objective, the present invention adopts the following technical solution:

[0010] A method for preparing a stain-resistant flexible paving brick includes the following steps:

[0011] A. Prepare the green body and dry it;

[0012] B. Apply a top glaze to form a top glaze layer;

[0013] C. Print colored ink according to the preset pattern to form an inkjet printing layer;

[0014] D. Apply polishing glaze to form a polished glaze layer;

[0015] E. After drying, it is fired in a kiln and then polished to obtain a polished semi-finished product;

[0016] F. Abrasion-resistant and stain-resistant coating is dripped onto the surface of the polished semi-finished product, and then polished using an ultra-clean polishing machine to form a stain-resistant film layer, resulting in stain-resistant soft-polished brick; wherein, the abrasion-resistant and stain-resistant coating includes a binder and a curing agent, the binder includes hydrogenated silicone oil, organosilicon resin, 903 glue and solvent; the raw materials of the 903 glue include heavy calcium carbonate and 707 water-soluble resin; the curing agent is a silane coupling agent.

[0017] Further, in step F, the wear-resistant and stain-resistant coating comprises 80-95% binder and 5-20% curing agent by mass percentage.

[0018] Further, in step F, the adhesive comprises, by mass percentage, 5-20% hydrogenated silicone oil, 3-15% silicone resin, 5-20% 903 adhesive, and 45-87% solvent.

[0019] Furthermore, the hydrogen content of the hydrogenated silicone oil is 1.50 to 2.50% by mass percentage.

[0020] Further, in step F, the silicone resin is a polyalkylaryl silicone resin;

[0021] The polyalkylaryl silicone resin includes either polymethylphenyl silicone resin or polyethylphenyl silicone resin.

[0022] The curing agent includes any one of γ-aminopropyltriethoxysilane, γ-glycidoxypropyltrimethoxysilane and γ-methacryloxypropyltrimethoxysilane;

[0023] The solvent includes at least one of anhydrous ethanol, ethylene glycol, polyethylene glycol, terpineol, and propylene glycol.

[0024] Furthermore, in step F, the particle size of the wear-resistant and stain-resistant coating is 30-50 nm;

[0025] The thickness of the stain-resistant membrane layer is 2–5 μm.

[0026] Furthermore, in step F, the polishing speed is 1000-1500 r / min, and the polishing time is 5-10 s.

[0027] Further, in step E, the specific method of polishing is as follows: first, the surface of the soft-polished brick is coarsely polished using an elastic grinding block installed on the polishing machine; then, the surface of the soft-polished brick is initially finely polished using a water-grinding pad installed on the polishing machine; and finally, the surface of the soft-polished brick is finely polished again using a water-grinding pad installed on the ultra-clean polishing machine.

[0028] Further, in step E, the number of groups of elastic grinding blocks is 3 to 12, the number of elastic grinding blocks in each group is 2 to 8, and the mesh size of the elastic grinding blocks is 120 to 500 mesh; the number of groups of water polishing pads is 2 to 8, the number of water polishing pads in each group is 2 to 8, and the mesh size of the water polishing pads is 120 to 420 mesh.

[0029] A stain-resistant soft-polished brick is prepared using the above-mentioned method for preparing a stain-resistant soft-polished brick. The soft-polished brick has a gloss of 13-35° and a stain resistance rating of 5.

[0030] The technical solutions provided in this application embodiment may include the following beneficial effects:

[0031] 1. When the surface of the semi-finished product is polished using an ultra-clean polishing machine, the surface temperature of the semi-finished product is high due to frictional heat. At high temperature, the solvent in the adhesive evaporates due to the curing agent. The hydrogenated silicone oil, silicone resin and 903 glue in the wear-resistant and stain-resistant coating are bonded and fixed in the pores of the semi-finished product surface, filling the pores after polishing and removing polishing scratches. The coating is then cured to form a smooth and delicate stain-resistant film layer that adheres to the surface of the semi-finished product. The stain-resistant film layer itself ensures the stain resistance of the soft-polished brick.

[0032] 2. The curing agent silane coupling agent acts as a bonding and bridging agent. It forms chemical bonds at the bonding interface between the polished semi-finished product surface and the stain-resistant film layer, so that the stain-resistant film layer is firmly adhered to the polished semi-finished product surface. This makes the stain-resistant film layer not easy to fall off even in daily use, giving the soft polished tile a long-lasting stain resistance.

[0033] 3. In this technical solution, the wear-resistant and stain-resistant coating uses a two-component combination of adhesive and curing agent. During curing, the inside and outside are cured simultaneously, and the curing depth is not limited. This avoids the defects of single-component curing, which is limited in curing depth and difficult to cure completely, by curing gradually from the surface to the inside. This further ensures the strong adhesion between the stain-resistant film layer and the surface of the polished semi-finished product, and also helps to improve the stain resistance and durability of the soft polished brick. Detailed Implementation

[0034] This technical solution provides a method for preparing stain-resistant flexible paving bricks, including the following steps:

[0035] A. Preparing the green body;

[0036] B. Print colored ink according to the preset pattern to form an inkjet printing layer;

[0037] C. Apply a top glaze to form a top glaze layer;

[0038] D. After drying, it is fired in a kiln and then polished to obtain a polished semi-finished product;

[0039] E. Abrasion-resistant and stain-resistant coating is dripped onto the surface of the polished semi-finished product, and then polished using an ultra-clean polishing machine to form a stain-resistant film layer, resulting in stain-resistant soft-polished brick; wherein, the abrasion-resistant and stain-resistant coating includes a binder and a curing agent, the binder includes hydrogenated silicone oil, organosilicon resin, 903 glue and solvent; the raw materials of the 903 glue include heavy calcium carbonate and 707 water-soluble resin; the curing agent is a silane coupling agent.

[0040] To overcome the technical problem that existing technologies cannot simultaneously achieve both soft gloss and durable stain resistance in soft-polished bricks, this technical solution proposes a method for preparing stain-resistant soft-polished bricks, including five steps: A (battery preparation), BC (application of surface glaze), C (printing color ink), D (application of polishing glaze), E (firing and polishing), and F (formation of a stain-resistant film layer). By innovating the formulation of wear-resistant and stain-resistant coatings combined with the polishing process of wear-resistant and stain-resistant coatings, soft-polished bricks can simultaneously achieve both soft gloss and durable stain resistance, meeting usage requirements.

[0041] Specifically, this technical solution proposes a wear-resistant and stain-resistant coating, the raw materials of which include a binder and a curing agent. The binder includes hydrogenated silicone oil, organosilicon resin, 903 adhesive, and a solvent. When the surface of the semi-finished product is polished using an ultra-clean polishing machine, the surface temperature of the semi-finished product is high due to frictional heat. At high temperature, the curing agent causes the solvent in the binder to evaporate. The hydrogenated silicone oil, organosilicon resin, and 903 adhesive in the wear-resistant and stain-resistant coating bond and fix to the pores on the surface of the semi-finished product, filling the pores after polishing and removing polishing scratches. It then cures to form a smooth and delicate stain-resistant film layer that adheres to the surface of the semi-finished product. The stain-resistant film layer itself ensures the stain resistance of the soft-polished brick. In addition, the curing agent silane coupling agent acts as a bonding bridging agent, forming chemical bonds at the bonding interface between the surface of the semi-finished product and the stain-resistant film layer, making the stain-resistant film layer firmly adhere to the surface of the semi-finished product. This makes the stain-resistant film layer less likely to fall off even in daily use, giving the soft-polished brick durable stain resistance. In addition, the wear-resistant and stain-resistant coating in this technical solution uses a two-component combination of adhesive and curing agent. During curing, the inside and outside are cured simultaneously, and the curing depth is not limited. This avoids the defects of single-component curing, which is limited in curing depth and difficult to cure completely, by curing gradually from the surface to the inside. This further ensures the strong adhesion between the stain-resistant film layer and the surface of the polished semi-finished product, and also helps to improve the stain resistance and durability of the soft polished brick.

[0042] More specifically, the binder's raw materials include hydrogenated silicone oil and silicone resin. Both hydrogenated silicone oil and silicone resin contain silicon atoms. Due to the special structure of silicon atoms, both hydrogenated silicone oil and silicone resin have low surface tension. Through the interaction of hydrogenated silicone oil and silicone resin, the wear-resistant and stain-resistant coating formulation is endowed with excellent stain resistance, improving the stain resistance of the stain-resistant film layer. At the same time, hydrogenated silicone oil contains strongly polar hydroxyl groups. Under the action of the curing agent, hydrogenated silicone oil and silicone resin undergo a cross-linking reaction to form a network structure. This not only further increases the bonding strength between the cured stain-resistant film layer and the surface of the polished semi-finished product, improving the stain resistance durability of the soft-polished brick, but also helps to give the stain-resistant film layer high hardness and wear resistance after curing, preventing the stain-resistant film layer from being easily worn away during cleaning of the soft-polished brick, thus improving the stain resistance durability. In addition, hydrogenated silicone oil has excellent lubrication properties, which helps to improve the lubrication performance of the wear-resistant and stain-resistant coating, thereby reducing the wear of the stain-resistant film layer during the cleaning of the soft-polished brick and improving the stain resistance durability.

[0043] Furthermore, the adhesive also includes 903 glue and a solvent. 903 glue is a conventional product whose raw material includes heavy calcium carbonate, which can fill pores and remove scratches. Simultaneously, because the texture of heavy calcium carbonate is similar to that of soft-polished tiles, it ensures the surface of the tiles retains a soft gloss after polishing, guaranteeing their smooth finish. Additionally, heavy calcium carbonate has a Mohs hardness of 3-4, which is relatively high and helps improve the wear resistance of the stain-resistant film, thus ensuring its durability. Besides, 903 glue also includes 707 water-soluble resin. 707 water-soluble resin helps improve the film-forming properties of the wear-resistant and stain-resistant coating, and also improves the filling effect of the stain-resistant film on pores and scratch removal after polishing. The solvent helps to dissolve and mix the components evenly and adjusts the viscosity of the wear-resistant and stain-resistant coating, allowing it to form a uniform stain-resistant film on the surface of the polished semi-finished product, ensuring the smooth finish and durable stain resistance of the soft-polished tiles.

[0044] Therefore, this technical solution uses a silane coupling agent, hydrogenated silicone oil, organosilicon resin, 903 adhesive, and solvent to formulate a wear-resistant and stain-resistant coating. When the soft-polished brick is heated by friction using an ultra-clean polishing machine, the wear-resistant and stain-resistant coating fills the pores generated after polishing and removes polishing scratches, and cures to form a smooth and delicate stain-resistant film layer. The stain-resistant film layer itself has stain-resistant properties, giving the soft-polished brick stain resistance. At the same time, the stain-resistant film layer firmly adheres to the surface of the polished semi-finished product, making it difficult for the stain-resistant film layer to fall off even in daily use, giving the soft-polished brick long-lasting stain resistance.

[0045] More specifically, existing polishing processes for wear-resistant and stain-resistant coatings generally include two types: angle polishing and ultra-gloss polishing. When using an angle polishing machine, the machine tends to sway from side to side during polishing, leading to uneven polishing. This makes it difficult to achieve a uniform stain-resistant film even if the film itself is relatively uniform, resulting in inconsistent stain resistance and affecting the durability of the glaze. Therefore, this technical solution uses ultra-gloss polishing, which ensures a more uniform stain-resistant film after polishing, thus guaranteeing the durability of the soft-polished tiles' stain resistance. Simultaneously, ultra-gloss polishing can remove stains and scratches from the surface of the semi-finished polished product, further improving the stain resistance of the soft-polished tiles. It should be noted that in step S6 of this technical solution, a soft pad and wool felt are sequentially installed on the bottom of the ultra-gloss polishing machine to buffer vibrations or shaking during polishing, preventing excessive vibration or shaking from damaging the tiles.

[0046] Preferably, in step A, the specific method for preparing the blank is as follows: pressing the ceramic blank using a concave-convex mold or a flat mold, and then drying it to obtain the blank.

[0047] Preferably, in step S1, the drying temperature is 170–190°C and the drying time is 30–60 min.

[0048] In a preferred embodiment of this technical solution, the drying time and temperature of the green body are optimized to ensure complete drying and avoid defects such as blisters during the application of the base glaze. If the drying temperature is too high or the drying time is too long, it will not significantly reduce blisters; if the drying temperature is too low or the drying time is too short, it will increase the moisture content of the green body, reduce its strength, and affect losses.

[0049] It should be noted that the body in this design is made from conventional ceramic blanks that have been pressed and dried; therefore, the ceramic blanks will not be described further here. The glazes applied to both the surface glaze and the polished glaze are conventional glazes used in the ceramic industry; therefore, the surface glaze and polished glaze will not be described further here. Furthermore, both the surface glaze and the polished glaze can be applied by spraying or dipping; this is not a limitation.

[0050] To further explain, in step F, the wear-resistant and stain-resistant coating comprises 80-95% binder and 5-20% curing agent by mass percentage.

[0051] When too much hardener is added, the curing time of the wear-resistant and stain-resistant coating is too short, which is not conducive to construction and has limited filling effect. Furthermore, when too much hardener is added, the performance of the stain-resistant film layer is limited, which is not conducive to ensuring stain resistance durability. When too little hardener is added, the curing time of the wear-resistant and stain-resistant coating is too long, resulting in excessive construction time and hindering production efficiency. Therefore, in a preferred embodiment of this technical solution, the formulation of the wear-resistant and stain-resistant coating is optimized to ensure ease of construction and stain resistance durability.

[0052] To further explain, in step F, the adhesive comprises, by mass percentage, 5-20% hydrogenated silicone oil, 3-15% silicone resin, 5-20% 903 adhesive, and 45-87% solvent.

[0053] The higher the amount of hydrogenated silicone oil added, the better the stain resistance of the wear-resistant and stain-resistant coating, but also the longer the curing time. The higher the amount of silicone resin added, the better the film-forming effect of the wear-resistant and stain-resistant coating, the stronger the bond with the surface of the polished brick, and the more fully it fills the pores. The higher the amount of 903 adhesive added, the better it ensures the smoothness of the polished brick and improves its stain resistance durability. The solvent is mainly used to adjust the viscosity; the higher its amount added, the lower the viscosity of the wear-resistant and stain-resistant coating, and the easier it is to form a uniform stain-resistant film. Based on the role of each component and the influence of its addition amount on the performance of the wear-resistant and stain-resistant coating, this technical solution optimizes the proportion of each component in the binder to ensure the best performance of the resulting wear-resistant and stain-resistant coating.

[0054] To further clarify, the hydrogen content of the hydrogenated silicone oil is 1.50 to 2.50% by mass percentage.

[0055] The higher the hydrogen content of hydrogenated silicone oil, the better its stain resistance. However, excessive hydrogen content in hydrogenated silicone oil can easily increase production costs. Therefore, this technical solution limits the hydrogen content of hydrogenated silicone oil to ensure the performance of wear-resistant and stain-resistant coatings at a lower cost.

[0056] To further clarify, in step F, the silicone resin is a polyalkylaryl silicone resin;

[0057] The polyalkylaryl silicone resin includes either polymethylphenyl silicone resin or polyethylphenyl silicone resin.

[0058] The curing agent includes any one of γ-aminopropyltriethoxysilane, γ-glycidoxypropyltrimethoxysilane and γ-methacryloxypropyltrimethoxysilane;

[0059] The solvent includes at least one of anhydrous ethanol, ethylene glycol, polyethylene glycol, terpineol, and propylene glycol.

[0060] Polyalkylaryl silicone resin is a copolymer of two types of resins: polyalkyl silicone resin and polyaryl silicone resin. The addition of one type to the other alters the resin composition, but it's not a simple mixture. Instead, during synthesis, the alkyl and aryl groups are directly attached to the same silicon atom, or a copolymer is formed through the hydrolysis and co-condensation of alkyl and aryl chlorosilanes. Therefore, polyalkylaryl silicone resin exhibits better mechanical properties and hardness than pure alkyl or aryl silicone resins. Thus, using polyalkylaryl silicone resin in this technical solution is more beneficial in ensuring the hardness and wear resistance of the stain-resistant film layer, thereby improving the stain resistance and durability of the flexibly polished brick.

[0061] Furthermore, the silane coupling agent is preferably any one of γ-aminopropyltriethoxysilane (KH-550), γ-glycidoxypropyltrimethoxysilane (KH-560), and γ-methacryloyloxypropyltrimethoxysilane (KH-570), thereby ensuring that it can firmly adhere the anti-fouling film layer to the surface of the polished semi-finished product and ensure anti-fouling durability.

[0062] Furthermore, the organic solvents include at least one of anhydrous ethanol, ethylene glycol, polyethylene glycol, terpineol, and propylene glycol. After the wear-resistant and stain-resistant coating has cured to form a stain-resistant film, it has basically evaporated completely, without affecting the gloss and weather resistance of the stain-resistant film. Moreover, the above solvents have low pollution and good environmental performance.

[0063] To further clarify, in step F, the particle size of the wear-resistant and stain-resistant coating is 30–50 nm;

[0064] The thickness of the stain-resistant membrane layer is 2–5 μm.

[0065] In a preferred embodiment of this technical solution, when the particle size of the wear-resistant and stain-resistant coating is greater than 50 nm, the excessively large particle size makes it difficult to fully fill and protect the surface of the polished semi-finished product. Furthermore, the resulting stain-resistant film layer lacks smoothness and density, which is detrimental to improving its stain resistance. Conversely, when the particle size of the nano-stain-resistant wax is less than 30 nm, the preparation difficulty increases. Therefore, this technical solution limits the wear-resistant and stain-resistant coating to 30–50 nm to ensure that the resulting stain-resistant protective layer is sufficiently smooth and dense, thereby ensuring its functionality.

[0066] Furthermore, the thickness of the stain-resistant film layer is 2 to 5 μm. This avoids the problem that if the stain-resistant film layer is too thin, there will be insufficient effective stain-resistant components, resulting in poor stain resistance. It also avoids the problem that if the stain-resistant film layer is too thick, it will increase the production cost and process difficulty of the stain-resistant flexible polished brick.

[0067] To further explain, in step F, the polishing speed is 1000-1500 r / min, and the polishing time is 5-10 s.

[0068] In a preferred embodiment of this technical solution, by limiting the grinding speed and grinding time in step E, the grinding effect is optimized, ensuring the stain resistance and soft gloss effect of the polished bricks.

[0069] To further explain, in step E, the specific method of polishing is as follows: first, the surface of the soft-polished brick is coarsely polished using an elastic grinding block installed on an angle polishing machine, and then the surface of the soft-polished brick is finely polished using a water-grinding disc installed on an ultra-clean polishing machine.

[0070] In a preferred embodiment of this technical solution, the surface of the soft-polished tile is first coarsely polished using an elastic abrasive block to remove glaze burrs and eliminate pinpoint shine. However, since the elastic abrasive block is mounted on an angular polishing machine that swings left and right, the polishing process is prone to uneven local gloss. Therefore, this technical solution, after coarsely polishing the surface of the soft-polished tile with an elastic abrasive block, then uses a water-based polishing pad mounted on an ultra-clean polishing machine to finely polish the surface of the soft-polished tile, removing scratches left by the coarse polishing and making the glaze gloss uniform. This also helps to reduce pores and scratches generated during the polishing process and lowers the difficulty of polishing with the ultra-clean polishing machine.

[0071] To further explain, in step E, the number of sets of elastic grinding blocks is 3 to 12, the number of elastic grinding blocks in each set is 2 to 8, and the mesh size of the elastic grinding blocks is 120 to 500; the number of sets of water polishing pads is 2 to 8, the number of water polishing pads in each set is 2 to 8, and the mesh size of the water polishing pads is 120 to 420.

[0072] In a preferred embodiment of this technical solution, by limiting the number and mesh size of the elastic modules, as well as the number and mesh size of the water polishing pads, it is not only beneficial to obtain higher polishing efficiency at a lower cost and ensure the gloss uniformity of the soft-polished tiles, but also to reduce the holes and scratches generated during the polishing process and reduce the difficulty of ultra-clean polishing.

[0073] A stain-resistant soft-polished brick is prepared using the above-mentioned method for preparing a stain-resistant soft-polished brick. The soft-polished brick has a gloss of 13-35° and a stain resistance rating of 5.

[0074] This technical solution also proposes a stain-resistant soft polished brick with a gloss level of 13-35°, a soft gloss, and a stain resistance rating of 5, exhibiting good stain resistance and durability.

[0075] The technical solution of the present invention will be further illustrated below through specific embodiments.

[0076] Performance testing

[0077] Gloss effect: Observe the gloss effect of the glaze of the soft-polished brick with the naked eye.

[0078] Gloss: The gloss of the soft-polished bricks was tested using an LS191 ceramic gloss meter, and the test was performed in parallel 5 times. The average value of the 5 tests was taken.

[0079] Stain resistance: The stain resistance of the glaze of the product is tested using the test method of FB / T3810.14-2016 "Test Methods for Ceramic Tiles Part 14: Determination of Stain Resistance - Building Materials Standard", with green dye in light oil as the staining agent. A stain resistance level of 5 is considered qualified.

[0080] Stain resistance durability: The glazed surface of the polished tile was rubbed back and forth with a Φ0.2mm steel wool ball 10,000 times. Then, the stain resistance of the polished tile was tested according to the test method of FB / T3810.14-2016 "Test Methods for Ceramic Tiles Part 14: Determination of Stain Resistance - Building Materials Standard". The test was performed in parallel for 5 times and the average value of the 5 measurements was taken.

[0081] Example 1

[0082] A. Prepare ceramic blanks, press the ceramic blanks using a concave and convex mold, and dry them at 170℃ for 60 minutes to obtain the blanks;

[0083] B. Apply a top glaze to form a top glaze layer;

[0084] C. Print colored ink according to the preset pattern to form an inkjet printing layer;

[0085] D. Apply polishing glaze to form a polished glaze layer;

[0086] E. After drying, the bricks are fired in a kiln and then polished to obtain polished semi-finished products. The specific polishing method is as follows: first, the surface of the soft-polished bricks is coarsely polished using elastic abrasive blocks installed on the polishing machine; then, the surface of the soft-polished bricks is initially finely polished using water-based polishing pads installed on the polishing machine; finally, the surface of the soft-polished bricks is finely polished again using water-based polishing pads installed on the ultra-clean polishing machine. The mesh sizes of the elastic abrasive blocks installed on the polishing machine are 120 mesh, 160 mesh, 200 mesh, 300 mesh, 400 mesh, and 500 mesh, with each mesh size representing one group, and a total of 6 groups, each containing 5 elastic abrasive blocks of the same mesh size. The mesh sizes of the water-based polishing pads installed on the polishing machine are 240 mesh, 300 mesh, 350 mesh, and 420 mesh, with each mesh size representing one group, and a total of 4 groups, each containing 6 water-based polishing pads of the same mesh size. The mesh size of the water-based polishing pads installed on the ultra-clean polishing machine is 420 mesh, and there are 6 water-based polishing pads in total.

[0087] F. A wear-resistant and stain-resistant coating with a particle size of 30 nm is dropped onto the surface of the polished semi-finished product. After polishing for 10 seconds using a super-clean polishing machine at a polishing speed of 1500 r / min, a stain-resistant film layer with a thickness of 3 μm is formed, resulting in a stain-resistant soft-polished tile. The wear-resistant and stain-resistant coating has a particle size of 30-50 nm and, by mass percentage, comprises 90% binder and 10% curing agent. By mass percentage, the binder comprises 10% hydrogenated silicone oil, 15% polymethyl phenyl silicone resin, 20% 903 adhesive, and 55% anhydrous ethanol. The raw materials of 903 adhesive include heavy calcium carbonate and 707 water-soluble resin. The curing agent is γ-aminopropyltriethoxysilane. By mass percentage, the hydrogen content of the hydrogenated silicone oil is 1.50%.

[0088] Example 2

[0089] A. Prepare ceramic blanks, press the ceramic blanks using a flat mold, and dry them at 170℃ for 60 minutes to obtain the blanks;

[0090] B. Apply a top glaze to form a top glaze layer;

[0091] C. Print colored ink according to the preset pattern to form an inkjet printing layer;

[0092] D. Apply polishing glaze to form a polished glaze layer;

[0093] E. After drying, the bricks are fired in a kiln and then polished to obtain polished semi-finished products. The specific polishing method is as follows: first, the surface of the soft-polished bricks is coarsely polished using elastic abrasive blocks installed on the polishing machine; then, the surface of the soft-polished bricks is initially finely polished using water-based polishing pads installed on the polishing machine; finally, the surface of the soft-polished bricks is finely polished again using water-based polishing pads installed on the ultra-clean polishing machine. The mesh sizes of the elastic abrasive blocks installed on the polishing machine are 120 mesh, 140 mesh, 180 mesh, 200 mesh, 250 mesh, and 300 mesh, with each mesh size representing one group, for a total of 30 elastic abrasive blocks. The mesh sizes of the water-based polishing pads installed on the polishing machine are 120 mesh, 150 mesh, 200 mesh, and 250 mesh, with each mesh size representing one group, for a total of 4 groups, each group containing 6 water-based polishing pads of the same mesh size. The mesh size of the water-based polishing pads installed on the ultra-clean polishing machine is 250 mesh, and there are 6 of them.

[0094] F. A 40nm abrasion-resistant and stain-resistant coating is dropped onto the surface of the polished semi-finished product. After polishing for 8 seconds using a super-clean polishing machine at a speed of 1000r / min, a stain-resistant film layer with a thickness of 5μm is formed, resulting in a stain-resistant soft-polished tile. The abrasion-resistant and stain-resistant coating comprises, by mass percentage, 80% binder and 20% curing agent. The binder comprises, by mass percentage, 5% hydrogenated silicone oil, 10% polymethylphenyl silicone resin, 10% 903 adhesive, and 75% polyethylene glycol. The raw materials for the 903 adhesive include heavy calcium carbonate and 707 water-soluble resin. The curing agent is γ-methacryloyloxypropyltrimethoxysilane. The hydrogen content of the hydrogenated silicone oil is 2.00% by mass percentage.

[0095] Example 3

[0096] A. Prepare ceramic blanks, press the ceramic blanks using a flat mold, and dry them at 170℃ for 60 minutes to obtain the blanks;

[0097] B. Apply a top glaze to form a top glaze layer;

[0098] C. Print colored ink according to the preset pattern to form an inkjet printing layer;

[0099] D. Apply polishing glaze to form a polished glaze layer;

[0100] After drying, the bricks are fired in a kiln and then polished to obtain polished semi-finished products. The specific polishing method is as follows: first, the surface of the soft-polished brick is coarsely polished using elastic abrasive blocks installed on the polishing machine; then, the surface of the soft-polished brick is initially finely polished using water-based polishing pads installed on the polishing machine; finally, the surface of the soft-polished brick is finely polished again using water-based polishing pads installed on the ultra-clean polishing machine. The mesh sizes of the elastic abrasive blocks installed on the polishing machine are 120 mesh, 160 mesh, 200 mesh, 300 mesh, 400 mesh, and 500 mesh, with each mesh size representing one group, and a total of 6 groups, each group containing 5 elastic abrasive blocks of the same mesh size. The mesh sizes of the water-based polishing pads installed on the polishing machine are 240 mesh, 300 mesh, 400 mesh, and 500 mesh, with each mesh size representing one group, and a total of 4 groups, each group containing 6 water-based polishing pads of the same mesh size. The mesh size of the water-based polishing pads installed on the ultra-clean polishing machine is 500 mesh, and there are 6 water-based polishing pads in total.

[0101] F. A wear-resistant and stain-resistant coating with a particle size of 50nm is dropped onto the surface of the polished semi-finished product. After polishing for 10 seconds using a super-clean polishing machine at a polishing speed of 1000r / min, a stain-resistant film layer with a thickness of 2μm is formed, resulting in a stain-resistant soft-polished tile. The wear-resistant and stain-resistant coating comprises, by mass percentage, 95% binder and 5% curing agent. The binder comprises, by mass percentage, 20% hydrogenated silicone oil, 5% polyethylphenyl silicone resin, 5% 903 adhesive, and 70% ethylene glycol. The raw materials for the 903 adhesive include heavy calcium carbonate and 707 water-soluble resin. The curing agent is γ-glycidyl etheroxypropyltrimethoxysilane. The hydrogen content of the hydrogenated silicone oil is 2.50% by mass percentage.

[0102] Comparative Example 1

[0103] The preparation methods and raw materials of Comparative Example 1 and Example 1 are the same, except that the wear-resistant and stain-resistant coating component in Comparative Example 1 is dimethylsiloxane.

[0104] Comparative Example 2

[0105] The preparation methods and raw materials of Comparative Example 2 are the same as those of Example 1. The difference is that Comparative Example 2 uses commercially available super-brightening agents. The super-brightening agent is an alkaline aqueous solution of silica sol with a silica sol content of 12 wt% and a pH value of 9.

[0106] Comparative Example 3

[0107] The preparation methods and raw materials of Comparative Example 3 are the same as those of Example 1. The difference is that the adhesive in Comparative Example 3 does not include 903 glue. That is, the adhesive includes 10% hydrogenated silicone oil, 15% polymethyl phenyl silicone resin and 65% anhydrous ethanol.

[0108] Table 1. Test results of relevant performance of stain-resistant flexural bricks

[0109] Experiment number Gloss effect Glossiness (°) Stain resistance Stain resistance and durability Example 1 Soft luster 20 Level 5 Level 5 Example 2 Soft luster 15 Level 5 Level 5 Example 3 Soft luster 35 Level 5 Level 5 Comparative Example 1 Soft luster 22 Level 3 Level 1 Comparative Example 2 The luster is dazzling 82 Level 4 Level 3 Comparative Example 3 The luster is dazzling 45 Level 5 Level 3

[0110] As can be seen from the test results in Table 1, the stain-resistant soft polished brick prepared by the method has a gloss of 13-35°, a soft gloss, and a stain resistance of level 5, which shows good stain resistance and long-lasting stain resistance.

[0111] In Comparative Example 1, the use of small-molecule silicone oil dimethylsiloxane as a wear-resistant and stain-resistant coating resulted in a stain-resistant film layer that could not be stably adhered to the surface of the polished semi-finished product, leading to poor stain resistance durability.

[0112] Comparative Example 2, due to the use of a super-cleaning brightener, resulted in a soft-polished tile with a high gloss level, which could not meet the usage requirements.

[0113] Comparative Example 3, due to the absence of 903 adhesive, i.e., the absence of heavy calcium carbonate in the stain-resistant film layer, resulted in an increase in the gloss of the stain-resistant film layer and a decrease in its durability.

[0114] 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 preparing a stain-resistant flexible polished brick, characterized in that: Includes the following steps: A. Prepare the green body and dry it; B. Apply a top glaze to form a top glaze layer; C. Print colored ink according to the preset pattern to form an inkjet printing layer; D. Apply polishing glaze to form a polished glaze layer; E. After drying, it is fired in a kiln and then polished to obtain a polished semi-finished product; F. Apply wear-resistant and stain-resistant coating to the surface of the polished semi-finished product, and then polish it with an ultra-clean and bright machine to form a stain-resistant film layer, thus obtaining stain-resistant soft polished brick; The wear-resistant and stain-resistant coating comprises, by weight percentage, 80-95% binder and 5-20% curing agent; The adhesive comprises, by weight percentage, 5-20% hydrogenated silicone oil, 3-15% silicone resin, 5-20% 903 adhesive, and 45-87% solvent; The raw materials for the 903 adhesive include heavy calcium carbonate and 707 water-soluble resin. The curing agent is a silane coupling agent.

2. The method for preparing a stain-resistant flexible polished brick according to claim 1, characterized in that: The hydrogen content of the hydrogenated silicone oil is 1.50 to 2.50% by mass percentage.

3. The method for preparing a stain-resistant flexible polished brick according to claim 1, characterized in that: step In F, the organosilicon resin is a polyalkylaryl organosilicon resin; The polyalkylaryl silicone resin includes either polymethylphenyl silicone resin or polyethylphenyl silicone resin. The curing agent includes any one of γ-aminopropyltriethoxysilane, γ-glycidoxypropyltrimethoxysilane and γ-methacryloxypropyltrimethoxysilane; The solvent includes at least one of anhydrous ethanol, ethylene glycol, polyethylene glycol, terpineol, and propylene glycol.

4. The method for preparing a stain-resistant flexible polished brick according to claim 1, characterized in that: In step F, the particle size of the wear-resistant and stain-resistant coating is 30-50 nm; The thickness of the stain-resistant membrane layer is 2–5 μm.

5. The method for preparing a stain-resistant flexible polished brick according to claim 1, characterized in that: In step F, the polishing speed is 1000-1500 r / min, and the polishing time is 5-10 s.

6. The method for preparing a stain-resistant flexible polished brick according to claim 1, characterized in that: In step E, the specific method of polishing is as follows: first, the surface of the soft-polished brick is coarsely polished using an elastic grinding block installed on the polishing machine; then, the surface of the soft-polished brick is initially finely polished using a water-grinding pad installed on the polishing machine; and finally, the surface of the soft-polished brick is finely polished again using a water-grinding pad installed on the ultra-clean polishing machine.

7. The method for preparing a stain-resistant flexible polished brick according to claim 6, characterized in that: In step E, the number of sets of elastic grinding blocks is 3 to 12, the number of elastic grinding blocks in each set is 2 to 8, and the mesh size of the elastic grinding blocks is 120 to 500; the number of sets of water polishing pads is 2 to 8, the number of water polishing pads in each set is 2 to 8, and the mesh size of the water polishing pads is 120 to 420.

8. A stain-resistant flexible polished brick, characterized in that, The slab is prepared using the method described in any one of claims 1 to 7, wherein the slab has a gloss of 13 to 35° and a stain resistance rating of 5.