A sanitary ceramic art glaze with leather texture and preparation method thereof

Abstract

The present invention discloses a sanitary ceramic art glaze with a leather-like texture and a preparation method thereof. The sanitary ceramic art glaze comprises a base glaze and a top glaze. The base glaze comprises the following ingredients by weight: 25-35 parts potassium feldspar, 4-6 parts kaolin, 5-7 parts aluminum oxide, 12-16 parts calcite, 12-16 parts zinc oxide, 18-24 parts calcium phosphate, 8-10 parts zirconium silicate, 2-4 parts cobalt black pigment, 0.5-1 part dark green pigment, and 0.2-0.3 part sodium carbonate. The present invention achieves an overall leather-like artistic effect while providing a smooth, stain-resistant, self-cleaning glaze surface, making it particularly suitable for decorative art glazes for sanitary ceramics and sanitary ware.

Description

Technical Field

[0001] The present invention relates to the field of sanitary ceramics, in particular to an artistic glaze for sanitary ceramics. Background Art

[0002] Existing sanitary ceramics are primarily white glazed. This is primarily due to the fact that many decorative glazes are unsuitable for complex sanitary ceramic shapes. For example, kiln-fired glazes require high-temperature fluidity, making large toilets and basins prone to excessive glaze thickness, leading to cracks. Crackle glazes can trap dirt inside the body, causing odor and difficulty in cleaning, making them unsuitable for sanitary ware that is exposed to contaminants over a long period of time. Crystallized glazes have extremely stringent requirements regarding glaze thickness, firing temperature, and atmosphere, making them unsuitable for tunnel kilns used in sanitary ware.

[0003] In the current market, the decorative glazes of sanitary ceramics are mostly colorful matte artistic glazes, and the glazes are homogeneous. Summary of the Invention

[0004] The main purpose of the present invention is to provide a sanitary ceramic art glaze. The sanitary ceramic art glaze provided by the present invention has a leather texture and is suitable for tunnel kiln firing of sanitary ware.

[0005] The technical solution adopted by the present invention to solve its technical problem is:

[0006] A sanitary ceramic artistic glaze with a leather texture comprises a base glaze of the following ingredients, measured by mass: 25-35 parts of potassium feldspar, 4-6 parts of kaolin, 5-7 parts of aluminum oxide, 12-16 parts of calcite, 12-16 parts of zinc oxide, 18-24 parts of calcium phosphate, 8-10 parts of zirconium silicate, 2-4 parts of cobalt black material, 0.5-1 part of dark green material, and 0.2-0.3 part of sodium carbonate.

[0007] In a preferred embodiment, the base glaze includes the following ingredients, calculated by mass: 25 parts of potassium feldspar, 4 parts of kaolin, 5 parts of aluminum oxide, 16 parts of calcite, 16 parts of zinc oxide, 24 parts of calcium phosphate, 10 parts of zirconium silicate, 4 parts of cobalt black material, 1 part of dark green material, and 0.2 parts of sodium carbonate.

[0008] In another preferred embodiment, the base glaze includes the following ingredients, by mass: 30 parts of potassium feldspar, 5 parts of kaolin, 6 parts of aluminum oxide, 14 parts of calcite, 14 parts of zinc oxide, 20 parts of calcium phosphate, 10 parts of zirconium silicate, 3 parts of cobalt black material, 1 part of dark green material, and 0.2 parts of sodium carbonate.

[0009] In another preferred embodiment, the base glaze includes the following ingredients, by mass: 35 parts of potassium feldspar, 6 parts of kaolin, 7 parts of aluminum oxide, 12 parts of calcite, 12 parts of zinc oxide, 18 parts of calcium phosphate, 8 parts of zirconium silicate, 2 parts of cobalt black material, 0.5 parts of dark green material, and 0.3 parts of sodium carbonate.

[0010] In the present invention, the leather-textured sanitary ceramic art glaze further includes a top glaze. Furthermore, the top glaze is self-cleaning. In a preferred embodiment, the top glaze comprises the following ingredients, by weight: 25-30 parts quartz, 30-35 parts potassium feldspar, 12-16 parts calcite, 1-3 parts zinc oxide, 1-4 parts aluminum oxide, 4-6 parts kaolin, 2-6 parts calcined talc, 6-8 parts wollastonite, and 0.2-0.3 parts sodium carbonate.

[0011] Another object of the present invention is to provide a method for preparing the sanitary ceramic artistic glaze having a leather texture, comprising the following steps:

[0012] Step 1: grind the base glaze according to the ratio of material to water = 100: (40-50), ball mill until the particle size is less than 10 μm and the cumulative proportion is 70%-75%. After exiting the mill, sieve to remove iron, adjust the glaze slurry performance to a flow rate of 50s / 100ml-60s / 100ml with CMC (hydroxymethyl cellulose), and spray it on the body to a thickness of 0.3mm-0.4mm.

[0013] Step 2: Put the top glaze into the mill according to the ratio of material: water = 100: (40-50), ball mill until the particles with a size of less than 10μm account for 78%-82% in total, then sieve out the iron removal, adjust the glaze slurry performance to a flow rate of 40s / 100ml-50s / 100ml with CMC, and spray it on the base glaze with a thickness of 0.2mm-0.3mm.

[0014] Step three: firing in a shuttle kiln or tunnel kiln.

[0015] In a preferred embodiment, in step three, the sintering temperature is controlled at 1200° C. to 1250° C. and the temperature is kept at this temperature for 0.5 h to 0.8 h.

[0016] In a preferred embodiment, in step three, the sintering is performed in an oxidizing atmosphere.

[0017] In a preferred embodiment, the base glaze is fed into the mill at a ratio of material to water of 100:42, and ball-milled to a particle size of <10μ with a cumulative proportion of 72%. After exiting the mill, the glaze is sieved to remove iron, and the glaze slurry performance is adjusted to a flow rate of 55s / 100ml with CMC, and then sprayed on the body with a thickness of 0.4mm; then the top glaze is sprayed with a thickness of 0.2mm, and fired in an oxidizing atmosphere in a shuttle kiln at a firing temperature of 1250°C for 0.8h.

[0018] Compared with the background technology, this technical solution has the following advantages:

[0019] 1. The difference of the base glaze of the present invention is mainly reflected in that conventional ceramic glazes are based on the formula idea of ​​using silicon and aluminum as glass network formers and maintaining silicon saturation, while the base glaze formula of the present invention reduces the conventional silicon content of 70-75% to 35-40%, and replaces part of the silicon with phosphorus to form a network structure. During the high-temperature firing process, the surface glaze has a higher potassium and sodium content and melts first, while the base glaze is still in the stage of decomposition and exhaust. The surface glaze will form an uneven initial texture due to the decomposition and exhaust of the body and base glaze; after the temperature continues to rise, the base glaze and the surface glaze are completely melted, but because the base glaze has a high zinc, calcium, and phosphorus content and a large surface tension, the base glaze will further agglomerate and form wrinkles along with the initial texture; the surface glaze has a higher potassium, sodium, and silicon content and a lower surface tension, and will spread on the surface of the base glaze to form a smooth and flat surface. Because the base glaze adds more phosphorus to replace silicon, the high-temperature viscosity is improved, and a large difference in composition is maintained, so that the base glaze remains at the bottom and does not affect the smooth and anti-fouling effect of the surface glaze layer.

[0020] 2. The top glaze is the conventional transparent, glossy and self-cleaning glaze in the sanitary ceramics industry, which ensures the functionality of the sanitary ware glaze, such as low roughness, not easy to stain and easy to clean. However, by adjusting the base glaze formula and differentiating the composition with the top glaze, a leather texture touch and appearance effect is formed, enriching the decorative effect of sanitary ceramics.

[0021] 3. The present invention ultimately forms an artistic effect of an overall leather texture, while the surface is a smooth, stain-resistant, self-cleaning glaze surface, which is more suitable for decorative art glazes for sanitary ceramics and sanitary ware. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention will be further described below with reference to the accompanying drawings and examples.

[0023] Figure 1 The present invention relates to a whole-body leather art glaze product.

[0024] Figure 2 The invention discloses a leather art glaze product with partially decorated colors.

[0025] Figure 3 This is a physical picture of the leather art glaze of Example 1.

[0026] Figure 4 This is a real-life picture of the leather art glaze of Example 2.

[0027] Figure 5 This is a real-life picture of the leather art glaze of Example 3.

[0028] Figure 6 This is a physical picture of the leather art glaze of Comparative Example 1.

[0029] Figure 7 This is a physical picture of the leather art glaze of Comparative Example 2. DETAILED DESCRIPTION

[0030] Example 1

[0031] Prepare a base glaze with the following ingredients in parts by mass: 25 parts potassium feldspar, 4 parts kaolin, 5 parts aluminum oxide, 16 parts calcite, 16 parts zinc oxide, 24 parts calcium phosphate, 10 parts zirconium silicate, 4 parts cobalt black material, 1 part dark green material, and 0.2 parts sodium carbonate.

[0032] Example 2

[0033] Prepare a base glaze with the following ingredients in parts by mass: 30 parts potassium feldspar, 5 parts kaolin, 6 parts aluminum oxide, 14 parts calcite, 14 parts zinc oxide, 20 parts calcium phosphate, 10 parts zirconium silicate, 3 parts cobalt black material, 1 part dark green material, and 0.2 parts sodium carbonate.

[0034] Example 3

[0035] Prepare a base glaze with the following ingredients in parts by mass: 35 parts potassium feldspar, 6 parts kaolin, 7 parts aluminum oxide, 12 parts calcite, 12 parts zinc oxide, 18 parts calcium phosphate, 8 parts zirconium silicate, 2 parts cobalt black material, 0.5 parts dark green material, and 0.3 parts sodium carbonate.

[0036] Comparative Example 1

[0037] Prepare the base glaze with the following ingredients in parts by mass: 24 parts quartz, 25 parts potassium feldspar, 4 parts kaolin, 5 parts aluminum oxide, 16 parts calcite, 16 parts zinc oxide, 0 parts calcium phosphate, 10 parts zirconium silicate, 4 parts cobalt black material, 1 part dark green material, and 0.2 parts sodium carbonate.

[0038] Comparative Example 2

[0039] Prepare the base glaze with the following ingredients in parts by mass: 10 parts quartz, 29 parts potassium feldspar, 4 parts kaolin, 5 parts aluminum oxide, 16 parts calcite, 3 parts zinc oxide, 24 parts calcium phosphate, 10 parts zirconium silicate, 4 parts cobalt black material, 1 part dark green material, and 0.2 parts sodium carbonate.

[0040]

[0041] The above embodiments and comparative examples all use the same glaze, which comprises, by mass:

[0042] Quartz 30, potassium feldspar 35, calcite 12, zinc oxide 2, aluminum oxide 3, kaolin 4, burned talc 5, wollastonite 6, sodium carbonate 0.3.

[0043] In the above embodiments and comparative examples, the ingredients were prepared according to the above ratio. The base glaze was fed into the mill at a ratio of 100:42 of base glaze to water, and ball milled until the particles with a particle size of less than 10 μm accounted for 72% of the total. After exiting the mill, the glaze was sieved to remove iron, and the glaze slurry properties were adjusted to a flow rate of 55 s / 100 ml with CMC, and then sprayed on the green body to a thickness of 0.4 mm.

[0044] The top glaze is put into the mill at a ratio of material: water = 100:42, and ball-milled to a particle size of <10μm with a cumulative proportion of 80%. After leaving the mill, it is sieved to remove iron, and the glaze slurry performance is adjusted to a flow rate of 45s / 100ml with CMC, and sprayed on the base glaze with a thickness of 0.2mm.

[0045] The shuttle kiln is used for firing in an oxidizing atmosphere, the firing temperature is controlled at 1250℃, and the temperature is kept at this temperature for 0.8h. The heating stage is:

[0046] Room temperature -80℃, 50min; 80-700℃, 240min; 700-1050℃, 90min; 1050-1100℃, 90min; 1100-1250℃, 70min; the temperature is increased at a uniform rate in each heating stage. The results are as follows:

[0047]

[0048] Examples 1 to 3 primarily vary the ratio of feldspar to that of calcite, zinc oxide, and calcium phosphate, adjusting for compositional differences with the top glaze. All of these examples have a leather-like texture, with relatively low roughness, not significantly different from conventional glaze roughness, ranging from 0.07 to 0.1 μm. The glaze's ease of cleaning is not significantly affected. Example 2 offers the best overall results, with low glaze roughness, optimal cleanability, and a strong leathery texture.

[0049] Comparative Example 1 differs from Example 1 in that calcium phosphate is not added, but quartz is used instead. The glaze can achieve a weak leather texture, but the glaze surface is relatively rough. Because the base glaze viscosity of Comparative Example 1 is lower than that of Example 1, the large difference in surface tension between the base glaze and the top glaze, coupled with low viscosity, leads to a more intense glaze reaction, making it difficult to achieve a smooth glaze surface, severely affecting the glaze's ease of cleaning and making it unsuitable for sanitary ceramic glazes.

[0050] Comparative Example 2 differs from Example 1 in that a lower proportion of zinc oxide is added, replacing it with quartz. The glaze does not develop a leathery texture. Because the zinc oxide content is low, the base glaze begins to degas earlier. When the top glaze melts, the base glaze also begins to melt. This seals off the degassing in the body, making it less likely to form early wrinkles that could trigger further reactions and changes between the base and top glazes.

[0051] The above description is merely a preferred embodiment of the present invention and therefore cannot be used to limit the scope of the present invention. In other words, equivalent changes and modifications made according to the scope of the present invention and the contents of the specification should still fall within the scope of the present invention.

Claims

1. A sanitary ceramic art glaze with a leather texture, characterized by: A base glaze comprising the following ingredients, by mass: 25-35 parts of potassium feldspar, 4-6 parts of kaolin, 5-7 parts of aluminum oxide, 12-16 parts of calcite, 12-16 parts of zinc oxide, 18-24 parts of calcium phosphate, 8-10 parts of zirconium silicate, 2-4 parts of cobalt black pigment, 0.5-1 part of dark green pigment, and 0.2-0.3 part of sodium carbonate; It also includes a glaze; the glaze includes the following ingredients by mass: 25-30 parts of quartz, 30-35 parts of potassium feldspar, 12-16 parts of calcite, 1-3 parts of zinc oxide, 1-4 parts of aluminum oxide, 4-6 parts of kaolin, 2-6 parts of calcined talc, 6-8 parts of wollastonite, and 0.2-0.3 parts of sodium carbonate.

2. The sanitary ceramic art glaze with leather texture according to claim 1, characterized in that: The base glaze includes the following ingredients by mass: 25 parts of potassium feldspar, 4 parts of kaolin, 5 parts of aluminum oxide, 16 parts of calcite, 16 parts of zinc oxide, 24 parts of calcium phosphate, 10 parts of zirconium silicate, 4 parts of cobalt black material, 1 part of dark green material, and 0.2 parts of sodium carbonate.

3. The sanitary ceramic art glaze with leather texture according to claim 1, characterized in that: The base glaze includes the following ingredients by mass: 30 parts of potassium feldspar, 5 parts of kaolin, 6 parts of aluminum oxide, 14 parts of calcite, 14 parts of zinc oxide, 20 parts of calcium phosphate, 10 parts of zirconium silicate, 3 parts of cobalt black material, 1 part of dark green material, and 0.2 parts of sodium carbonate.

4. The sanitary ceramic art glaze with leather texture according to claim 1, characterized in that: The base glaze includes the following ingredients by mass: 35 parts of potassium feldspar, 6 parts of kaolin, 7 parts of aluminum oxide, 12 parts of calcite, 12 parts of zinc oxide, 18 parts of calcium phosphate, 8 parts of zirconium silicate, 2 parts of cobalt black material, 0.5 parts of dark green material, and 0.3 parts of sodium carbonate.

5. The method for preparing a sanitary ceramic artistic glaze with leather texture according to claim 1, characterized in that: The steps include: Step 1: Prepare the base glaze by mixing the material and water at a ratio of 100: (40-50). Mill the base glaze until the particle size is less than 10µm and the cumulative proportion is 70%-75%. After exiting the mill, sieve the glaze to remove iron. Adjust the glaze slurry performance with CMC to a flow rate of 50s / 100ml-60s / 100ml. Spray the glaze onto the body to a thickness of 0.3mm-0.4mm. Step 2: For the top glaze, mix the material: water = 100: (40-50) and grind it into a mill. Ball mill it until the particle size is less than 10µm and the cumulative proportion is 78%-82%. After it is removed from the mill, it is sieved to remove iron. The glaze slurry performance is adjusted to a flow rate of 40s / 100ml~50s / 100ml with CMC. Spray it on the base glaze to a thickness of 0.2mm~0.3mm. Step three: firing using a shuttle kiln or tunnel kiln.

6. The method for preparing a sanitary ceramic artistic glaze having a leather texture according to claim 5, characterized in that: In step 3, the firing temperature is controlled at 1200°C to 1250°C and kept at this temperature for 0.5 h to 0.8 h.

7. The method for preparing a sanitary ceramic artistic glaze having a leather texture according to claim 6, characterized in that: In step three, firing is performed in an oxidizing atmosphere.

8. The method for preparing a sanitary ceramic artistic glaze having a leather texture according to claim 5, characterized in that: The base glaze is ground into the mill at a ratio of material: water = 100:42, and ball-milled to a particle size of <10µ, with a cumulative proportion of 72%. After being discharged from the mill, it is sieved to remove iron, and the glaze slurry performance is adjusted to a flow rate of 55s / 100ml with CMC, and sprayed on the body with a thickness of 0.4mm.

9. The method for preparing a sanitary ceramic artistic glaze having a leather texture according to claim 8, characterized in that: After spraying the base glaze, spray the top glaze 0.2mm, and use a shuttle kiln to fire in an oxidizing atmosphere. The firing temperature is controlled at 1250℃ and kept warm for 0.8h.

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