A dry particle composition, a whole rock board and a preparation method thereof

Abstract

The present invention discloses a dry particle composition, a solid rock slab and a preparation method thereof, belonging to the field of material technology. The dry particle layer formed by the dry particle composition in the solid rock slab product, after being combined with a surface glaze layer, not only has an ideal texture refinement and a high degree of stone simulation due to its special composition, but is almost the same as natural stones such as marble under reflection, and has a delicate quicksand texture without affecting the wear resistance and stain resistance of the product.

Description

Technical Field

[0001] The present invention relates to the field of material technology, and in particular to a dry particle composition, a solid rock slab and a preparation method thereof. Background Art

[0002] Solid rock slabs with the effect of natural stone are gaining popularity in a wider range of home renovations due to their unique stone texture. Traditional solid rock slabs are either painted with a base material during production or produced using a machine-made spreading process, resulting in a less than ideal texture. Furthermore, even if they possess a certain stone texture, the surface doesn't feel like real stone upon contact, resulting in a low degree of fidelity. For this reason, some imitation stone solid rock slabs are treated with surface treatments to roughen their feel, closer to stone texture. However, this approach reduces the product's wear resistance and stain resistance. Summary of the Invention

[0003] Based on the defects of the existing technology, the purpose of the present invention is to provide a dry particle composition. Due to its special composition, when applied to the whole rock slab, this product not only has an ideal texture and exquisite feeling, but also has a high degree of stone simulation, and is almost the same as natural stones such as marble under reflection. At the same time, it has a delicate quicksand texture and does not affect the wear resistance and stain resistance of the product.

[0004] In order to achieve the above object, the technical solution adopted by the present invention is:

[0005] A dry granular composition comprising the following chemical components in percentage by weight:

[0006] SiO2 45~60%, Al2O3 15~20%, SrO 3.5~7%, K2O 5~8%, Na2O 1~5%, MgO0.3~1%, CaO 2~5%, ZnO 3~6% and BaO 5~10%.

[0007] In the prior art, the surface texture formed by using colorants or mechanical spreading is difficult to combine with the blank, and it is impossible to present the texture of refined stone. At the same time, the surface of the product cannot replicate the texture of stone. For this reason, in the technical solution of the present invention, the inventor provides a dry particle composition that can be added to the whole body rock board. The composition has a high content of barium oxide and potassium oxide, which can increase the refractive index of the product, thereby increasing the gloss of the brick surface and improving the clarity of the texture when applied to the whole body rock board. At the same time, the product uses alkaline earth metal oxides such as strontium oxide, zinc oxide, and calcium oxide and two alkali metal oxide components, sodium oxide and potassium, as composite components. The solvent-like system improves the stability of the product. After firing, the product contains calcium feldspar, celsium feldspar, and zinc-aluminum spinel crystal phases. After the solid rock slab is fired, these crystals have a strong diffuse reflection effect on light. Therefore, the glaze formed by it forms a three-dimensional texture effect of different depths and shapes under the action of the ink pattern; based on the specific types and composition of chemical components, the product not only has natural and clear stone rock slab textures and a strong three-dimensional sense, but also has a feel similar to quicksand and a very realistic texture; on the other hand, after the product is applied to the solid rock slab, it has good wear resistance and high flatness, so it will not hide dirt and grime, and has excellent stain resistance.

[0008] Preferably, the mesh size of the dry granular composition is greater than or equal to 250 mesh.

[0009] More preferably, the mesh size of the dry granular composition is 250 to 300 meshes.

[0010] It should be noted that the dry granular composition of the present invention inevitably contains impurities and loss on ignition, and the impurities and loss on ignition are generally not higher than 10%.

[0011] Preferably, the raw materials for preparing the dry granular composition include the following components in parts by weight:

[0012] 5-8 parts of strontium carbonate, 3-7 parts of zinc oxide, 2-5 parts of potassium carbonate, 1-4 parts of dolomite, 3-10 parts of calcite, 35-45 parts of potassium feldspar, 10-15 parts of sodium feldspar, 8-15 parts of air knife clay, 5-7 parts of quartz, 2-7 parts of aluminum oxide and 8-15 parts of barium carbonate.

[0013] More preferably, the raw materials for preparing the dry granular composition include the following components in parts by weight:

[0014] 5-8 parts of strontium carbonate, 3-5 parts of zinc oxide, 2-5 parts of potassium carbonate, 2-4 parts of dolomite, 5-8 parts of calcite, 40-45 parts of potassium feldspar, 10-13 parts of sodium feldspar, 8-10 parts of air knife clay, 5-7 parts of quartz, 5-7 parts of aluminum oxide and 9-15 parts of barium carbonate.

[0015] The inventors have found through experiments that during the preparation process of the dry granular composition, after introducing sufficient amounts of barium carbonate and potassium feldspar, the amount of air knife soil added is controlled so that the chemical components contained therein can be maintained at just the appropriate ratio, and the above preferred ratio is used for compounding.

[0016] More preferably, the dry granular composition comprises the following chemical components in percentage by weight:

[0017] SiO2 45-52%, Al2O3 16-18%, SrO 3.5-4.5%, K2O 6-7.5%, Na2O1-1.55%, MgO 0.4-1%, CaO 4-5%, ZnO 4-6% and BaO 8.5-10%.

[0018] The inventors have discovered that after firing, when the chemical composition of the dry granular composition, such as calcium oxide, zinc oxide, and barium oxide, is within the above-mentioned preferred range, the particles of the dry granular composition are round, have good color, high transparency, and high stability. Therefore, the prepared product has better overall performance, especially in terms of feel and surface texture, with a high degree of fineness of feel and high clarity of texture effect.

[0019] Another object of the present invention is to provide a method for preparing the dry granular composition, comprising the following steps:

[0020] The raw materials for preparing the dry granular composition are mixed, and then melt-fired, cooled, crushed, and sieved in sequence to obtain the dry granular composition.

[0021] Preferably, the temperature during the melt firing is 1500-1600° C., and the time is 3-10 hours.

[0022] The preparation method of the dry granular composition of the present invention has simple operating steps, low equipment requirements, and can be implemented for industrial-scale production.

[0023] Another object of the present invention is to provide a whole rock slab, comprising a green body layer, a bottom glaze layer, a top glaze layer, a printing layer and a dry particle layer adjacent to each other in sequence, wherein the dry particle layer comprises the dry particle composition of the present invention.

[0024] Preferably, the dry particle amount of the dry particle composition is 180-220 g / m 2 .

[0025] In order to provide realistic texture and feel of stone, the whole body rock board of the present invention adopts the special dry particle composition as the dry particle layer laid on the surface glaze layer and the printing layer, and no additional glaze layer or material layer is set. Based on the specific chemical composition and size of the dry particle composition, it not only has good texture permeability and delicate feel, but also has high laying flatness, high wear resistance under low friction coefficient, and no tendency to absorb dirt due to gaps or multiphase, fully meeting the anti-fouling standards.

[0026] Preferably, the glaze layer comprises a glaze composition, and the glaze composition comprises the following chemical components in percentage by weight:

[0027] SiO254~60%, Al2O320~25%, ZrO23~6%, K2O2~5%, Na2O3~5%, MgO0.5~1%, CaO3~5% and ZnO2~4%.

[0028] After introducing the dry particle layer, the inventor noticed through experiments that the surface glaze layer will actually affect the glossiness, surface particle size, etc. of the final prepared solid rock slab. The most important thing is that this influence will lead to the surface flatness and fineness of the product, which in turn will have a certain impact on the feel, texture clarity and even wear resistance of the product. When more silica is introduced but the aluminum content is low, the insufficient skeleton component of the formula will cause the glaze gloss to be too high, and the glaze layer fluidity is too high, and the glaze layer has poor high-temperature stability. The subsequently applied dry particle composition will have too high flatness after firing, the three-dimensional sense will deteriorate and the glossiness will be higher; otherwise, it will cause the dry particle laying flatness to be too small, which will cause the defects of rough feel and easy dirt absorption, and will also lead to texture color difference. When the surface glaze composition composed of the above-mentioned preferred chemical components is used to form the surface glaze layer, the product can have the best surface texture and feel, and at the same time, better wear resistance.

[0029] More preferably, the glaze composition comprises the following raw materials in parts by weight:

[0030] 5-10 parts of air knife clay, 5-10 parts of zirconium silicate, 5-10 parts of nepheline, 5-10 parts of quartz, 20-25 parts of potassium feldspar, 20-30 parts of sodium feldspar, 10-20 parts of calcined kaolin, 3-5 parts of zinc oxide, 5-8 parts of calcite, 10-15 parts of frit and 3-8 parts of calcined alumina;

[0031] The frit comprises the following components in parts by weight: 10-15 parts of kaolin, 15-20 parts of potassium feldspar, 20-30 parts of sodium feldspar, 10-15 parts of barium carbonate, 5-10 parts of dolomite, 5-10 parts of calcite, 1-3 parts of zinc oxide, 6-10 parts of aluminum oxide and 10-15 parts of quartz.

[0032] When preparing the glaze composition of the present invention, the types of materials are different, so the chemical composition of the prepared glaze layer will naturally be different. The glaze composition prepared by using air knife clay, nepheline and compound calcined alumina can achieve dual guarantees in terms of visual and performance.

[0033] More preferably, the raw materials for preparing the glaze composition are further subjected to grinding, iron removal and sieving processes.

[0034] More preferably, the mesh number of the sieving is ≤325 meshes.

[0035] Preferably, the green body layer comprises the following raw materials in parts by weight:

[0036] 5-10 parts of green body color particles, 90-95 parts of green body material particles;

[0037] More preferably, the green body pellets include the following raw materials in parts by weight:

[0038] 6-9 parts of potassium sodium sand, 25-35 parts of potassium sodium stone powder, 4-10 parts of talc, 15-25 parts of kaolin, 10-15 parts of quartz sand, 20-30 parts of ball clay, 10-15 parts of pyrophyllite, 0.1-0.2 parts of methyl cellulose, and 0.01-0.05 parts of sodium tripolyphosphate.

[0039] More preferably, the method for preparing the green body pellets comprises the following steps:

[0040] The raw materials are mixed and ground, spray granulated, and aged to obtain the green body granules.

[0041] More preferably, the blank color material includes but is not limited to gray material, black material, white material, yellow material and red material.

[0042] Furthermore, the body color material may be at least one of dark gray material, black material, extra black material, gray material, ordinary white material, light gray material, super white material, brown yellow material, and brown red material.

[0043] More preferably, the green body colorant comprises the following components in parts by weight:

[0044] 5-20 parts of dark gray material, 30-15 parts of black material, 3-5 parts of extra black material, 15-55 parts of gray material, 10-20 parts of ordinary white material, 5-15 parts of light gray material, 70-85 parts of ultra-white material, 3-5 parts of brown yellow material and 3-5 parts of brown red material.

[0045] The body layer of the present invention can be prepared by the above-mentioned formula of the present invention based on the appearance requirements and mechanical property requirements of the actual product, or by the body formula of the rock slab known to those skilled in the art. As long as it does not affect the performance effects of the dry particle layer and the glaze layer of the present invention, there is no restriction. Even if the materials of the above-mentioned formula are used, for example, the above-mentioned specific combination of colorants is used, the proportions thereof can still be freely matched according to requirements, and the above-mentioned ratios are not required to be followed. Additional colorants can also be further added, or at least one of the colorants can be deleted.

[0046] Preferably, the base glaze layer is prepared by white ink printing and texture ink application.

[0047] More preferably, the particle size of the white ink is ≤2 μm, the density is 1.26-1.46 g / mL, and the printing volume is 50-100 g / m 2 .

[0048] Another object of the present invention is to provide a method for preparing the solid rock slab, comprising the following steps:

[0049] The green body material particles and green body colorant are mixed and pressed into shape to obtain a green body layer;

[0050] Building a base glaze layer on the body layer;

[0051] Build a top glaze layer on the base glaze layer;

[0052] Building a printing layer on the glaze layer;

[0053] A dry particle layer is constructed on the printed layer to prepare a blank to be fired;

[0054] The blank to be fired is fired to obtain the solid rock slab.

[0055] The preparation method of the full-body rock slab described in the present invention is not much different from that of the existing full-body rock slabs, and the preparation operation steps are simple. However, based on the special dry particle layer and the application of the compound glaze layer, compared with the existing full-body rock slab products, not only can fine surface textures that are basically the same as natural stone be obtained (some existing rock slab products can be seen under reflection that there is still a certain gap between their surface textures and real stone, and the textures are not clear, which makes the product unable to have the luxury of natural stone), but the surface texture is more delicate and the general performance meets the standards.

[0056] Preferably, the pressure during the compression molding is 390-450 bar.

[0057] Preferably, the glaze layer and the dry particle layer are constructed by spraying.

[0058] Preferably, a protective glaze is provided on the printed layer.

[0059] Preferably, the firing temperature of the blank to be fired is 1100-1300° C., and the firing time is 60-100 minutes.

[0060] The beneficial effect of the present invention is that the present invention provides a dry particle composition and a solid rock slab prepared therefrom. The dry particle layer formed by the dry particle composition in the product, after being combined with a surface glaze layer, not only has an ideal texture refinement and a high degree of stone simulation based on its special composition, but is almost the same as natural stones such as marble under reflection, and has a delicate quicksand texture, and does not affect the wear resistance and stain resistance of the product.

[0061] Figures in the specification

[0062] Figure 1 This is a schematic diagram of the solid rock slab described in Example 2 of the present invention.

[0063] Figure 2 This is a schematic diagram of the full-body rock slab described in comparative example 7 of the present invention.

[0064] Figure 3 This is a schematic diagram of the solid rock slab described in Example 1 of the present invention.

[0065] Figure 4 This is a schematic diagram of an optical electron microscope of the dry particle composition on the solid rock slab described in Example 1 of the present invention.

[0066] Figure 5 This is a schematic diagram of an optical electron microscope of the dry particle composition on the solid rock slab described in Comparative Example 1 of the present invention.

[0067] Figure 6 This is a schematic diagram of an optical electron microscope of the dry particle composition on the solid rock slab described in Comparative Example 3 of the present invention.

[0068] Figure 7 This is a microscopically enlarged schematic diagram of the dry particle composition on the solid rock slab described in Example 1 of the present invention.

[0069] Figure 8 This is a microscopically enlarged schematic diagram of the dry particle composition on the whole rock slab described in Comparative Example 3 of the present invention. DETAILED DESCRIPTION

[0070] In order to better illustrate the purpose, technical solutions and advantages of the present invention, the present invention will be further described below in conjunction with specific embodiments and comparative examples. Its purpose is to understand the content of the present invention in detail, rather than to limit the present invention. All other embodiments obtained by those of ordinary skill in the art without making creative work premise all fall within the protection scope of the present invention. The experimental reagents and instruments involved in the implementation of the present invention are all conventional common reagents and instruments unless otherwise specified.

[0071] Example 1

[0072] An embodiment of a dry particle composition, a solid rock board, and a preparation method thereof according to the present invention comprises the following preparation steps:

[0073] (1) 85 parts of green body pellets and 15 parts of green body colorant were mixed and put into an automatic distributing machine for mixing, and pressed at 400 bar to obtain a green body layer;

[0074] The raw materials for preparing the green body pellets include the following components in parts by weight: 8 parts of potassium sodium sand, 35 parts of potassium sodium stone powder, 4 parts of talc, 25 parts of kaolin, 20 parts of ball clay, 10 parts of quartz sand, 10 parts of pyrophyllite, 0.1 parts of methyl cellulose and 0.03 parts of sodium tripolyphosphate;

[0075] The preparation method of the green body pellets is as follows: mixing the raw materials for preparation and ball milling for 12 hours, spray granulating, and aging for 48 hours to obtain the green body pellets;

[0076] The green body colorant comprises the following components in parts by weight:

[0077] 10 parts of dark gray material, 15 parts of black material, 5 parts of extra black material, 2 parts of brown yellow material, 3 parts of brown red material and 10 parts of light gray material;

[0078] (2) constructing a base glaze layer on the body layer;

[0079] During construction, firstly, a white ink with a particle size of less than 2 μm and a density of 1.3 g / mL was printed on the green body layer at a speed of 30 g / m 2 The amount of ink is jetted, and then the mold effect and fine effect pattern lines (within the range of 0.1 to 0.5 mm) are applied by hand-drawing with texture ink to form the base glaze layer;

[0080] (3) constructing a top glaze layer on the bottom glaze layer;

[0081] The raw materials of the glaze composition are sprayed on the base glaze layer to form a glaze layer. The spraying amount is 350g / m 2 , specific gravity is 1.45g / m 3 ;

[0082] The glaze composition comprises the following raw materials in parts by weight:

[0083] 8 parts of air knife clay, 5 parts of zirconium silicate, 5 parts of nepheline, 8 parts of quartz, 20 parts of potassium feldspar, 25 parts of sodium feldspar, 15 parts of calcined kaolin, 4 parts of zinc oxide, 6 parts of calcite, 12 parts of frit and 4 parts of calcined alumina;

[0084] The frit includes the following components in parts by weight: 15 parts of kaolin, 18 parts of potassium feldspar, 15 parts of sodium feldspar, 13 parts of barium carbonate, 8 parts of dolomite, 8 parts of calcite, 3 parts of zinc oxide, 8 parts of aluminum oxide and 12 parts of quartz.

[0085] The raw materials for preparing the glaze composition are pre-mixed, then ball-milled for 6 hours, iron removed by an electromagnet, and passed through a 325-mesh sieve;

[0086] (4) constructing a printing layer on the glaze layer;

[0087] The texture ink is transferred to the inkjet printer in the form of pattern data, so that the laser printing inkjet printer is consistent with the texture of the blank, and the surface texture and the blank texture are accurately aligned. This precise alignment can ensure high-precision full-body inkjet printing, and then the inkjet printer is heated to 190g / m 2 Spray protective glaze on the printed layer with a spraying amount of

[0088] (5) forming a dry particle layer on the printed layer to obtain a blank to be fired;

[0089] The dry granular composition was sprayed onto the printed layer at a spraying amount of 210 g / m 2 ;

[0090] The raw materials for preparing the dry granular composition include the following components in parts by weight:

[0091] 5 parts of strontium carbonate, 6 parts of zinc oxide, 4 parts of potassium carbonate, 2 parts of dolomite, 5 parts of calcite, 40 parts of potassium feldspar, 15 parts of sodium feldspar, 12 parts of air knife clay, 7 parts of quartz, 5 parts of aluminum oxide and 8 parts of barium carbonate.

[0092] The preparation method of the dry granular composition comprises the following steps:

[0093] The raw materials are mixed, melted and fired at 1530°C for 5 hours, quenched with water, crushed, and sieved to obtain a dry granular composition with a mesh size of 100 to 200 meshes;

[0094] (6) The blank to be fired is fired to obtain the solid rock slab.

[0095] The firing temperature is 1210° C. and the firing time is 80 minutes.

[0096] The chemical compositions of the glaze composition and the dry particle composition in the glaze layer and the dry particle layer of the whole rock slab are shown in Tables 1 and 2.

[0097] Example 2

[0098] An embodiment of a dry granular composition, a solid rock board, and a preparation method thereof according to the present invention differs from Example 1 only in that the raw materials for preparing the dry granular composition include the following components in parts by weight:

[0099] 5 parts of strontium carbonate, 5 parts of zinc oxide, 4 parts of potassium carbonate, 3 parts of dolomite, 6 parts of calcite, 40 parts of potassium feldspar, 13 parts of sodium feldspar, 10 parts of air knife clay, 7 parts of quartz, 7 parts of aluminum oxide and 10 parts of barium carbonate.

[0100] Example 3

[0101] An embodiment of a dry granular composition, a solid rock board, and a preparation method thereof according to the present invention differs from Example 1 only in that the raw materials for preparing the dry granular composition include the following components in parts by weight:

[0102] 5 parts of strontium carbonate, 7 parts of zinc oxide, 3 parts of potassium carbonate, 2 parts of dolomite, 5 parts of calcite, 40 parts of potassium feldspar, 15 parts of sodium feldspar, 12 parts of air knife clay, 7 parts of quartz, 6 parts of aluminum oxide and 7 parts of barium carbonate.

[0103] Example 4

[0104] An embodiment of a dry granular composition, a solid rock board, and a preparation method thereof according to the present invention differs from Example 1 only in that the raw materials for preparing the dry granular composition include the following components in parts by weight:

[0105] 5 parts strontium carbonate, 5 parts zinc oxide, 4 parts potassium carbonate, 2 parts dolomite, 6 parts calcite, 42 parts potassium feldspar, 15 parts sodium feldspar, 9 parts aerosol, 6 parts quartz, 6 parts aluminum oxide, and 9 parts barium carbonate.

[0106] Example 5

[0107] An embodiment of a dry granular composition, a solid rock slab, and a preparation method thereof according to the present invention differs from Example 1 only in that the raw materials for preparing the dry granular composition include the following parts by weight: 5 parts of strontium carbonate, 6 parts of zinc oxide, 4 parts of potassium carbonate, 2 parts of dolomite, 5 parts of calcite, 38 parts of potassium feldspar, 18 parts of sodium feldspar, 12 parts of air knife clay, 7 parts of quartz, 5 parts of aluminum oxide, and 7 parts of barium carbonate.

[0108] Example 6

[0109] An embodiment of a dry granular composition, a solid rock board, and a preparation method thereof according to the present invention differs from Example 1 only in that the raw materials for preparing the dry granular composition include the following components in parts by weight:

[0110] 5 parts of strontium carbonate, 5 parts of zinc oxide, 4 parts of potassium carbonate, 3 parts of dolomite, 6 parts of calcite, 43 parts of potassium feldspar, 13 parts of sodium feldspar, 10 parts of air knife clay, 5 parts of quartz, 5 parts of aluminum oxide and 9 parts of barium carbonate.

[0111] Example 7

[0112] An embodiment of a dry particle composition, a solid rock slab, and a preparation method thereof described in the present invention differs from Example 2 only in that the glaze composition includes the following preparation raw materials in parts by weight: 5 parts of air knife clay, 8 parts of zirconium silicate, 5 parts of nepheline, 6 parts of quartz, 22 parts of potassium feldspar, 25 parts of sodium feldspar, 13 parts of calcined kaolin, 4 parts of zinc oxide, 6 parts of calcite, 15 parts of frit, and 3 parts of calcined alumina.

[0113] Example 8

[0114] An embodiment of a dry particle composition, a solid rock slab, and a preparation method thereof described in the present invention differs from Example 2 only in that the glaze composition includes the following preparation raw materials in parts by weight: 8 parts of air knife clay, 6 parts of zirconium silicate, 6 parts of nepheline, 5 parts of quartz, 25 parts of potassium feldspar, 22 parts of sodium feldspar, 13 parts of calcined kaolin, 4 parts of zinc oxide, 5 parts of calcite, 14 parts of frit, and 4 parts of calcined alumina.

[0115] Comparative Example 1

[0116] A dry granular composition, a solid rock plate, and a preparation method thereof, which differ from Example 1 only in that the raw materials for preparing the dry granular composition include the following components in parts by weight:

[0117] 15 parts of calcined kaolin, 9 parts of zinc oxide, 6.5 parts of potassium carbonate, 5 parts of dolomite, 16 parts of wollastonite, 19 parts of potassium feldspar, 14 parts of sodium feldspar, 22 parts of quartz, and 2 parts of aluminum oxide.

[0118] Comparative Example 2

[0119] A dry granular composition, a solid rock plate, and a preparation method thereof, which differ from Example 1 only in that the raw materials for preparing the dry granular composition include the following components in parts by weight:

[0120] 10 parts of limestone, 6 parts of strontium carbonate, 5 parts of zinc oxide, 5 parts of dolomite, 14 parts of potassium feldspar, 30 parts of sodium feldspar, 7 parts of quartz, 9 parts of aluminum oxide, 10 parts of calcined kaolin and 13 parts of barium carbonate.

[0121] Comparative Example 3

[0122] A dry granular composition, a solid rock plate, and a preparation method thereof, which differ from Example 1 only in that the raw materials for preparing the dry granular composition include the following components in parts by weight:

[0123] 8 parts of strontium carbonate, 3 parts of zinc oxide, 6 parts of potassium carbonate, 2 parts of dolomite, 10 parts of calcite, 30 parts of potassium feldspar, 10 parts of sodium feldspar, 19 parts of air knife clay, 10 parts of quartz, 1 part of aluminum oxide and 10 parts of barium carbonate.

[0124] Comparative Example 4

[0125] A dry particle composition, a whole rock plate and a preparation method thereof, which differ from Example 2 only in that the glaze composition comprises the following raw materials in parts by weight:

[0126] 5 parts of wollastonite, 8 parts of zirconium silicate, 8 parts of nepheline, 20 parts of potassium feldspar, 22 parts of sodium feldspar, 15 parts of calcined kaolin, 4 parts of zinc oxide, 8 parts of calcite, 10 parts of frit, and 9 parts of quartz.

[0127] Comparative Example 5

[0128] A dry particle composition, a whole rock plate and a preparation method thereof, which differ from Example 2 only in that the glaze composition comprises the following raw materials in parts by weight:

[0129] 6 parts of barium carbonate, 7 parts of zirconium silicate, 20 parts of potassium feldspar, 25 parts of sodium feldspar, 16 parts of calcined kaolin, 5 parts of zinc oxide, 8 parts of calcite, 15 parts of frit and 10 parts of calcined alumina.

[0130] Comparative Example 6

[0131] A dry particle composition, a whole rock plate and a preparation method thereof, which differ from Example 2 only in that the glaze composition comprises the following raw materials in parts by weight:

[0132] 10 parts of air knife clay, 5 parts of zirconium silicate, 5 parts of nepheline, 13 parts of quartz, 15 parts of potassium feldspar, 18 parts of sodium feldspar, 15 parts of calcined kaolin, 6 parts of zinc oxide, 15 parts of calcite, 5 parts of frit and 5 parts of calcined alumina.

[0133] Comparative Example 7

[0134] An embodiment of a dry particle composition, a solid rock slab and a preparation method thereof is different from Example 1 only in that the solid rock slab does not construct a bottom glaze layer, but constructs a surface glaze layer directly on the body layer.

[0135] In addition, the dry particle compositions and glaze compositions described in Tables 1 and 2 also contain inevitable trace impurities or loss on ignition, which are not listed here one by one.

[0136] Table 1

[0137]

[0138]

[0139] Table 2

[0140]

[0141] Effect Example 1

[0142] In order to verify the use effect of the full-body rock slab of the present invention, the products prepared in each embodiment and comparative example were subjected to the following tests:

[0143] (1) Wear resistance test: Test the wear resistance grade according to GB / T3810.7-2016 standard;

[0144] (2) Stain resistance test: Test the stain resistance level according to GB / T3810.14 standard;

[0145] (3) Surface friction: The friction coefficient of the product is tested using the dry method in Appendix M of GB / T4100;

[0146] (4) Texture test: 10 testers were selected. First, they were asked to touch clean fine sand with their palms and let it flow away to feel the tactile sensation. Then, they were asked to touch the surface of the dry particle layer of the whole rock slab and score the texture they touched (blindfolded). The score ranged from 1 to 10 points (integer points). The higher the score, the closer the texture is to the unique flowing sand feeling of real stone sand, and the better the texture. At the same time, in order to avoid subjectivity and randomness, the order of samples was only informed to the testers by numbers. After completing one round of testing and recording the average score, the order was shuffled and the same test was repeated for two rounds. The average score of the three rounds of testing was recorded and only the middle score was recorded (for example, if the average score of a sample in the three rounds was 9.0, 9.5 and 9.8, 9.5 would be recorded).

[0147] (5) Grain evaluation test: 10 testers were selected to evaluate the surface grain of each product under reflected light, using marble as a control. The score ranged from 1 to 10 (integer points). The clearer the grain and the closer it is to the natural grain of natural marble under reflected light, the higher the score. The average score of each sample was calculated and recorded.

[0148] The test results are shown in Table 3.

[0149] Table 3

[0150]

[0151] It can be seen from the results that the whole rock board prepared by the dry particle composition of the present invention has ideal performance, the wear resistance level reaches level 3, the stain resistance level reaches level 5, and the static friction coefficient can be maintained in a small range of 0.4 to 0.6. At the same time, when evaluating the texture and appearance, the texture score of the product can reach 9.2 points or more (that is, at least one tester gave each product a full score of 10 points). At the same time, Figure 1As shown, the product of Example 2 of the present invention has very clear and delicate imitation stone texture under reflection, with a natural and luxurious feel that fully reflects natural stone. Furthermore, Examples 1 to 6 show that texture and appearance are not directly related. For example, Example 5 has a high texture score, but a texture score of only 9.0. The products of Examples 2, 4, and 6 have even higher texture and appearance ratings, indicating that when using a dry granular composition with preferred ingredients to prepare a product, both texture and appearance can be improved.

[0152] In contrast, when the products of Comparative Examples 1 to 3 are prepared using different or the same raw materials, the chemical composition of the dry particle composition formed therefrom is not within the limited scope of the present invention. The final formed solid rock slabs not only fail to achieve the simulation of stone in texture and appearance, but may even cause the static friction coefficient of the product to increase, resulting in a decrease in the stain resistance of the product. On the other hand, during the preparation process of the products of Comparative Examples 4 to 6, based on the difference in the raw materials for the glaze preparation, the chemical composition of the glaze layer formed by the glaze composition is also different from that of the product of Example 2, resulting in defects in various aspects of the product's performance. For example, although the product of Comparative Example 4 has a high appearance score, its wear resistance and stain resistance are low, and its texture score is less than 9 points, which cannot meet the use standard. During the preparation process of the product of Comparative Example 7, no base glaze layer is provided. Although it is no different from the example in terms of performance, its texture and appearance scores are low. The products of Example 1 and Comparative Example 7 are visually compared under normal light. Figure 2 and 3 As shown, it can be clearly seen that it is difficult to see three-dimensional texture on the surface of the product described in Comparative Example 7, which fully illustrates the importance of the bottom glaze layer to the presentation of product texture.

[0153] The dry particle compositions on the tiles obtained in Example 1, Comparative Example 1 and Comparative Example 3 were observed by light electron microscopy. Figures 4-6 As shown, it can be seen that the dry particle composition particles in the solid rock slab of the present invention are sharp-edged and rounded, and the particles are evenly distributed; although the product of Comparative Example 1 has high stacking uniformity and density, it is not round enough and the particles are not uniform, and some particles are even sharp, so the texture when touched is naturally not ideal; and the product obtained in Comparative Example 3 has irregular particle size, and low stacking uniformity and stacking density, which not only has poor texture and grain effects, but also may cause unsatisfactory anti-fouling effect.

[0154] Furthermore, the dry granular composition on the dry granular layer described in Example 1 and Comparative Example 3 was observed under a microscope. Figure 7 and 8As shown, it can be seen that the dry granular composition of the present invention has a high degree of roundness, almost presenting a spherical shape, and a high bulk density, so it has a good texture, and also has good wear resistance and antifouling effects. However, the product of Comparative Example 3 actually also has an irregular appearance and almost no round shape, so the overall performance is not ideal. This fully demonstrates that when preparing a dry granular composition, in addition to paying attention to the selection of the raw material formula, the main thing to pay attention to is the selection of the chemical components. If the selection is inappropriate, even if the same raw materials are used, the same effect of the present invention cannot be achieved.

[0155] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that the technical solutions of the present invention may be modified or replaced by equivalents without departing from the essence and scope of the technical solutions of the present invention.

Claims

1. A full-body rock slab, characterized in that: It includes a body layer, a bottom glaze layer, a top glaze layer, a printing layer and a dry particle layer that are adjacent to each other in sequence; The dry particle layer includes a dry particle composition, and the dry particle composition includes the following chemical components in percentage by weight: SiO245~60%, Al2O315~20%, SrO3.5~7%, K2O 5~8%, Na2O 1~5%, MgO0.3~1%, CaO2~5%, ZnO3~6% and BaO5~10%; The glaze layer includes a glaze composition, and the glaze composition includes the following chemical components in percentage by weight: SiO254~60%, Al2O320~25%, ZrO23~6%, K2O2~5%, Na2O3~5%, MgO0.5~2%, CaO3~5% and ZnO2~4%.

2. The whole rock slab according to claim 1, characterized in that: The raw materials for preparing the dry granular composition include the following components in parts by weight: 5-8 parts of strontium carbonate, 3-7 parts of zinc oxide, 2-5 parts of potassium carbonate, 1-4 parts of dolomite, 3-10 parts of calcite, 35-45 parts of potassium feldspar, 10-15 parts of sodium feldspar, 8-15 parts of air knife clay, 5-7 parts of quartz, 2-7 parts of aluminum oxide and 8-15 parts of barium carbonate.

3. The whole rock slab according to claim 1, characterized in that: The dry granular composition comprises the following chemical components in percentage by weight: SiO245~52%, Al2O315~18%, SrO3.5~4.5%, K2O 6~7.5%, Na2O 1~1.55%, MgO0.4~1%, CaO4~5%, ZnO4~5% and BaO8.5~10%.

4. The whole rock plate according to claim 1, characterized in that: The preparation method of the dry granular composition comprises the following steps: The prepared raw materials are mixed, and then melt-fired, cooled, crushed, and sieved in sequence to obtain the dry granular composition; the temperature during the melt-fired process is 1500-1600° C., and the time is 3-10 hours.

5. The whole rock slab according to claim 1, characterized in that: The glaze composition comprises the following raw materials in parts by weight: 5-10 parts of air knife clay, 5-10 parts of zirconium silicate, 5-10 parts of nepheline, 5-10 parts of quartz, 20-25 parts of potassium feldspar, 20-30 parts of sodium feldspar, 10-20 parts of calcined kaolin, 3-5 parts of zinc oxide, 5-8 parts of calcite, 10-15 parts of frit and 3-8 parts of calcined alumina; The frit comprises the following components in parts by weight: 10-15 parts of kaolin, 15-20 parts of potassium feldspar, 20-30 parts of sodium feldspar, 10-15 parts of barium carbonate, 5-10 parts of dolomite, 5-10 parts of calcite, 1-3 parts of zinc oxide, 6-10 parts of aluminum oxide and 10-15 parts of quartz.

6. The whole rock slab according to claim 1, characterized in that: The green body layer comprises the following raw materials in parts by weight: 5~10 parts of green body color particles, 90~95 parts of green body material particles; The green body pellets include the following raw materials in parts by weight: 6-9 parts of potassium sodium sand, 25-35 parts of potassium sodium stone powder, 4-10 parts of talc, 15-25 parts of kaolin, 10-15 parts of quartz sand, 20-30 parts of ball clay, 10-15 parts of pyrophyllite, 0.1-0.2 parts of methyl cellulose, and 0.01-0.05 parts of sodium tripolyphosphate.

7. The whole rock slab according to claim 1, characterized in that: The base glaze layer is prepared by printing with white ink and applying texture ink; the particle size of the white ink is ≤2μm, the density is 1.26~1.46g / mL, and the printing volume is 50~100g / m 2 .

8. The method for preparing the whole rock slab according to any one of claims 1 to 7, characterized in that: The following steps are involved: The green body material particles and green body colorant are mixed and pressed to obtain a green body layer; the pressure during the pressing is 390-450 bar; Building a base glaze layer on the body layer; Build a top glaze layer on the base glaze layer; Building a printing layer on the glaze layer; A dry particle layer is constructed on the printed layer to prepare a blank to be fired; The blank to be fired is fired to obtain the solid rock slab; the firing temperature of the blank to be fired is 1100-1300° C., and the firing time is 60-100 minutes.

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