Ceramic tile having a bottom surface with holes and method for manufacturing the same

Abstract

The application discloses a ceramic tile with holes on the bottom surface, which comprises a hole layer and a surface layer arranged in sequence from bottom to top; the hole layer is obtained by calcining hole powder, and the surface layer is obtained by calcining surface layer powder; the content of aluminum oxide in the ceramic tile is 22-25% in terms of mass percentage; the hole powder comprises foaming powder and mullite type powder; the foaming powder comprises the following raw materials in terms of mass fraction: clay I 10-12 parts, polishing slag 8-12 parts, limestone 15-20 parts and fluxing agent I 53-67 parts; the surface layer powder and the mullite type powder both comprise clay II 17-31 parts, calcined coal gangue 1-3 parts, green gangue 15-18 parts, recycled material 10-16 parts and fluxing agent II 40-48 parts. The ceramic tile with holes on the bottom surface and the preparation method thereof can ensure the firmness of the ceramic tile under the premise of reducing the water absorption of the ceramic tile and improving the strength of the ceramic tile.

Description

Technical Field

[0001] This invention relates to the field of building ceramics technology, and in particular to a ceramic tile with holes on its bottom surface and its preparation method. Background Technology

[0002] Tiles are widely used in building decoration and renovation, especially in interior decoration, where they have become a primary material for wall and floor decoration. Tile installation typically involves using cement mortar or adhesives to bond tiles to wall and floor surfaces. However, to ensure tile strength, the water absorption rate of tiles is generally controlled below 3%. Because the water absorption rate is too low, cement mortar or adhesives cannot easily penetrate the tile body to form a strong bond with the wall or floor, resulting in poor tile adhesion.

[0003] To address the technical problem of poor tile adhesion, some technicians in the building decoration and renovation field have begun to add textured patterns to the bottom surface of tiles to increase their roughness and improve adhesion. While this method can increase adhesion to some extent, it still falls short of solving the adhesion problem caused by the low water absorption rate of tiles. In other words, the existing technology of adding textured patterns to the bottom surface of tiles has a very limited effect on improving tile adhesion. Summary of the Invention

[0004] The purpose of this invention is to provide a ceramic tile with holes on the bottom surface and its preparation method. The water absorption rate of the tile is <0.05%, the modulus of rupture is ≥47MPa, and the breaking strength is ≥2000N. Under the premise of reducing the water absorption rate and increasing the strength of the tile, the adhesive firmness of the tile is ensured, so as to overcome the shortcomings of the prior art.

[0005] To achieve this objective, the present invention adopts the following technical solution:

[0006] A ceramic tile with holes on its bottom surface includes a hole layer and a surface layer arranged sequentially from bottom to top; the hole layer is obtained by calcining hole powder, the surface layer is obtained by calcining surface layer powder, and the content of aluminum oxide in the ceramic tile is 22% to 25% by mass percentage.

[0007] The porous powder includes foamed powder and mullite-type powder; wherein, calculated by mass parts, the foamed powder includes the following raw materials: 10-12 parts of clay I, 8-12 parts of polishing slag, 15-20 parts of limestone and 53-67 parts of flux I;

[0008] According to the mass fractions, both the surface powder and the mullite-type powder include 17-31 parts of clay II, 1-3 parts of calcined coal gangue, 15-18 parts of green gangue, 10-16 parts of recycled material, and 40-48 parts of flux II.

[0009] Further, calculated by mass percentage, the chemical composition of the polishing slag includes CaO 1.6–1.7%, SiO2 63.1–63.2%, Fe2O3 1.4–1.5%, MgO 0.8–0.9%, TiO2 0.2–0.3%, Al2O3 20.2–20.3%, K2O 3.7–3.8%, and Na2O 1.9–2.0%, with the remainder being loss on ignition;

[0010] The chemical composition of the surface powder and the mullite powder, calculated by mass percentage, includes CaO 0.9-1.0%, SiO2 64-66%, MgO 0.3-0.4%, Al2O3 19-19.5%, K2O 3.8-4.2%, and Na2O 1.6-1.8%, with the remainder being loss on ignition.

[0011] Furthermore, calculated by mass percentage, the porous powder comprises 20-30% foamed powder and 70-80% mullite-type powder;

[0012] The limestone has a particle size of 5–7 mm.

[0013] Furthermore, the particle size distribution of the foamed powder is as follows: by mass percentage, the residue on a 20-mesh sieve is 0.3-0.5%, the residue on a 40-mesh sieve is 1.5-2.5%, the residue on a 60-mesh sieve is 55-65%, and the residue on a 100-mesh sieve is 97.5-98.5%.

[0014] Furthermore, the thickness of the porous layer is 2-3 mm, and the thickness of the surface layer is 7-8 mm.

[0015] Further, the clay II comprises bentonite, washed kaolin, and Luoshan clay, and the chemical composition of the Luoshan clay, calculated by mass percentage, includes CaO 1.2–1.3%, SiO2 68.5–68.6%, Fe2O3 3.2–3.3%, MgO 0.7–0.8%, TiO2 0.4–0.5%, Al2O3 13.9–14.0%, K2O 3.0–3.1%, and Na2O 1.1–1.3%, with the remainder being loss on ignition;

[0016] According to the mass fractions, both the surface layer powder and the mullite-type powder include 10-15 parts bentonite, 2-6 parts washed kaolin, 5-10 parts Luoshan clay, 1-3 parts calcined coal gangue, 15-18 parts green gangue, 10-16 parts recycled material, and 40-48 parts flux II.

[0017] Furthermore, the recycled materials include polishing mud, waste brick powder, and recycled brick blanks;

[0018] According to the mass fractions, both the surface layer powder and the mullite-type powder include 10-15 parts bentonite, 2-6 parts washed kaolin, 5-10 parts Luoshan clay, 1-3 parts calcined coal gangue, 15-18 parts green gangue, 5-7 parts polishing mud, 4-6 parts waste brick powder, 1-3 parts recycled raw material, and 40-48 parts flux II.

[0019] Furthermore, the clay I includes Honda clay and Dajiang black clay, and the mixing ratio of Honda clay and Dajiang black clay is (2-4):1 according to the mass ratio.

[0020] The chemical composition of the Honda clay, calculated by mass percentage, includes CaO 0.1–0.2%, SiO2 51.7–51.8%, Fe2O3 2.7–2.8%, MgO 0.6–0.7%, TiO2 0.4–0.5%, Al2O3 0.3–30.4%, K2O 2.9–3.0%, and Na2O 0.01–0.02%, with the remainder being loss on ignition.

[0021] The chemical composition of the Dajiang black mud, calculated by mass percentage, includes CaO 0.25–0.3%, SiO2 51.5–51.6%, Fe2O3 2.5–2.6%, MgO 0.6–0.7%, TiO2 0.3–0.4%, Al2O3 31.1–31.2%, K2O 2.7–2.8%, and Na2O 0.2–0.25%, with the remainder being loss on ignition.

[0022] Furthermore, the flux I comprises nepheline, potassium feldspar, and black talc, and the foaming powder comprises the following raw materials in parts by mass: 10-12 parts clay I, 8-12 parts polishing slag, 15-20 parts limestone, 25-30 parts nepheline, 20-25 parts potassium feldspar, and 8-12 parts black talc.

[0023] A method for preparing a ceramic tile with holes on its bottom surface, comprising the following steps:

[0024] A. Mix clay I, polishing residue, limestone and flux I evenly according to the formula to obtain foaming powder;

[0025] B. Mix clay II, calcined coal gangue, green gangue, recycled material and flux II evenly according to the formula to obtain mullite-type powder;

[0026] C. After mixing the foaming powder and the mullite powder evenly according to the formula, a porous powder is obtained.

[0027] D. After spreading the porous powder, a porous layer is obtained; take mullite-type powder as the surface powder, spread the surface powder on the top of the porous layer to obtain the surface layer, and after pressing and firing in a kiln, a ceramic tile with holes at the bottom is obtained; wherein, the firing temperature is 1120~1125℃, and the firing time is 35~40min.

[0028] The technical solution provided by this invention may include the following beneficial effects:

[0029] 1. In this technical solution, the porous powder is designed as a mixture of foamed powder and mullite-type powder. The limestone (whose main component is calcium carbonate) in the foamed powder decomposes during high-temperature calcination, producing and releasing carbon dioxide gas, thus leaving an irregular porous structure on the bottom surface of the tile. Simultaneously, the amount of flux I added to the foamed powder formulation is greater than that of flux II added to the mullite-type powder formulation. This results in the foamed powder forming a powder with a firing temperature of 1050–1100℃, while the mullite-type powder forms a powder with a firing temperature of 1120–1125℃, meaning the firing temperature of the foamed powder is lower than that of the mullite-type powder. Therefore, when the mullite-type powder in the porous powder begins to vitrify by forming a liquid phase, the completely melted foamed powder promotes the boiling of the liquid phase of the mullite-type powder, which also contributes to the formation of a large number of irregular porous structures.

[0030] 2. In this technical solution, the porous powder is a mixture of foamed powder and mullite powder. This allows for the generation of numerous irregular pores during the calcination process, while simultaneously utilizing the high strength of both the foamed and mullite powders to impart high strength to the porous layer. Furthermore, the formulation of the surface layer powder is the same as that of the mullite powder, further enhancing the surface layer's strength. Through the synergy between the porous layer and the surface layer, the ceramic tile achieves a modulus of rupture ≥47MPa and a breaking strength ≥2000N, demonstrating high strength. Detailed Implementation

[0031] This technical solution provides a ceramic tile with holes on the bottom surface, comprising a hole layer and a surface layer arranged sequentially from bottom to top; the hole layer is obtained by calcining hole powder, the surface layer is obtained by calcining surface layer powder, and the content of aluminum oxide in the ceramic tile is 22% to 25% by mass percentage.

[0032] The porous powder includes foamed powder and mullite-type powder; wherein, calculated by mass parts, the foamed powder includes the following raw materials: 10-12 parts of clay I, 8-12 parts of polishing slag, 15-20 parts of limestone and 53-67 parts of flux I;

[0033] According to the mass fractions, both the surface powder and the mullite-type powder include 17-31 parts of clay II, 1-3 parts of calcined coal gangue, 15-18 parts of green gangue, 10-16 parts of recycled material, and 40-48 parts of flux II.

[0034] To address the technical problem of weak adhesion of ceramic tiles in existing technologies, this technical solution proposes a ceramic tile with holes on its bottom surface, comprising a hole layer and a surface layer arranged sequentially from bottom to top. The hole layer is obtained by calcining hole powder, and the surface layer is obtained by calcining surface layer powder. The hole powder includes foaming powder and mullite powder. The surface layer powder and the mullite powder contain the same raw materials and have the same amount of raw materials. By optimizing the formulations of the foaming powder, mullite powder, and surface layer powder, the water absorption rate of the ceramic tile is reduced to <0.05%, the modulus of rupture is increased to ≥47MPa, and the breaking strength is increased to ≥2000N. This ensures the strong adhesion of the ceramic tile while reducing its water absorption rate and increasing its strength.

[0035] Specifically, existing travertine tiles generally consist of a bottom layer and a top layer stacked from bottom to top, and the perforated effect of travertine tiles only exists in the top layer. However, travertine tiles with perforations only in the top layer cannot solve the technical problem of weak tile adhesion in this technical solution. Therefore, the perforated tiles in this technical solution cannot be based on the above principle.

[0036] To improve the adhesion of tiles, this technical solution designs the porous powder as a mixture of foaming powder and mullite-type powder. The limestone (mainly calcium carbonate) in the foaming powder decomposes during high-temperature calcination, producing and releasing carbon dioxide gas, thus leaving an irregular porous structure on the bottom surface of the tile. Simultaneously, the amount of flux I added to the foaming powder formula is greater than that of flux II added to the mullite-type powder formula. This results in the foaming powder having a firing temperature of 1050–1100℃, while the mullite-type powder has a firing temperature of 1120–1125℃, meaning the firing temperature of the foaming powder is lower than that of the mullite-type powder. Therefore, when the mullite-type powder in the porous powder begins to vitrify by forming a liquid phase, the completely melted foaming powder promotes the boiling of the mullite-type powder liquid phase, which also contributes to the formation of a large number of irregular porous structures.

[0037] Therefore, this technical solution, by limiting the amount of limestone in the foaming powder formulation and the amount of flux I in the foaming powder formulation and flux II in the mullite-type powder formulation, creates a large number of irregular pores on the bottom surface of the tile. This allows the adhesive applied to the bottom surface of the tile to form a stable interlocking tenon-and-mortise structure with the tile body during installation, greatly enhancing the adhesion and meeting practical application requirements. Furthermore, compared to regular pore structures, irregular pore structures allow the adhesive to quickly enter the pores from multiple directions and angles, forming a more stable interlocking tenon-and-mortise structure with the tile body, further improving adhesion.

[0038] Meanwhile, the foaming powder in this technical solution also includes clay I and polishing slag. The main chemical component of clay I is silicon dioxide, which mainly plays a plasticizing and binding role and helps to improve strength. Adding it to the foaming powder can improve its plasticity, strength, and injection molding properties. Meanwhile, polishing slag is a solid waste generated during the polishing and grinding process of ceramic products (such as polished tiles and glazed tiles) to obtain a bright and smooth surface. Due to its high strength, it imparts high strength to the foaming powder. Therefore, this technical solution, by introducing clay I and polishing slag into the foaming powder and limiting the amount of these two raw materials added, enables the foaming powder to have high strength.

[0039] In addition, the raw materials for both surface layer powder and mullite-type powder include clay II, calcined coal gangue, green gangue, and recycled materials. The main chemical component of clay II is silicon dioxide, which is beneficial to improving the plasticity, strength, and grouting properties of surface layer powder and mullite-type powder. Coal gangue is the waste residue such as stone and mud left over from coal mining. Calcined coal gangue is the product obtained after coal gangue is calcined at high temperature, and its main component is aluminum oxide. The main component of green gangue is also aluminum oxide. In addition to reacting with the silicon dioxide in clay II to form mullite, the aluminum oxide in calcined coal gangue and green gangue itself has high mechanical strength and excellent wear resistance. When added to the surface layer powder and mullite-type powder formulation, it plays a supporting role in providing the skeleton, which is beneficial to improving the strength of the surface layer powder and mullite-type powder formulation. In addition, recycled materials, due to their high strength, are also beneficial to adjusting the strength of surface layer powder and mullite-type powder.

[0040] Therefore, this technical solution introduces clay II, calcined coal gangue, green gangue and recycled materials into the surface layer powder and mullite powder, and limits the amount of the above raw materials added, so that the surface layer powder and mullite powder have high strength.

[0041] Therefore, based on the formulation design of foamed powder and mullite powder, this technical solution uses a mixture of foamed powder and mullite powder as the porous powder. This allows for the generation of numerous irregular pores during the calcination process, while utilizing the high strength of both the foamed powder and the mullite powder, thus imparting high strength to the porous layer. Furthermore, the formulation of the surface layer powder is the same as that of the mullite powder, further enhancing the surface layer's strength. Through the synergy between the porous layer and the surface layer, the ceramic tile achieves a modulus of rupture ≥47MPa and a breaking strength ≥2000N, exhibiting high strength.

[0042] Furthermore, the aluminum oxide content in the ceramic tiles of this technical solution is as high as 22% to 25%, which is 3% to 5% higher than that in conventional ceramic tiles. This high aluminum oxide content facilitates the production of more mullite during the firing process, improving the structural strength of the ceramic tile and allowing it to maintain high strength even with numerous irregular pores on the bottom surface. Moreover, the optimized formulations of the foaming powder, mullite-type powder, and surface layer powder in this technical solution also help reduce the water absorption rate of the fired body, ensuring a water absorption rate of <0.05%, which further contributes to maintaining its strength.

[0043] It should be noted that the manufacturer of the calcined coal gangue in this technical solution is Shandong Zibo Hengli Trading Co., Ltd., and the model is 50 calcined gangue; the manufacturer of the green gangue is Yuanqu County Chengtaiyuan Trading Co., Ltd., and the model is 40 green gangue.

[0044] To further explain, the chemical composition of the polishing slag, calculated by mass percentage, includes CaO 1.6–1.7%, SiO2 63.1–63.2%, Fe2O3 1.4–1.5%, MgO 0.8–0.9%, TiO2 0.2–0.3%, Al2O3 20.2–20.3%, K2O 3.7–3.8%, and Na2O 1.9–2.0%, with the remainder being loss on ignition.

[0045] The chemical composition of the surface powder and the mullite powder, calculated by mass percentage, includes CaO 0.9-1.0%, SiO2 64-66%, MgO 0.3-0.4%, Al2O3 19-19.5%, K2O 3.8-4.2%, and Na2O 1.6-1.8%, with the remainder being loss on ignition.

[0046] The polishing slag, with its optimized chemical composition calculated by mass percentage, includes CaO 1.6–1.7%, SiO2 63.1–63.2%, Fe2O3 1.4–1.5%, MgO 0.8–0.9%, TiO2 0.2–0.3%, Al2O3 20.2–20.3%, K2O 3.7–3.8%, and Na2O 1.9–2.0%, with a SiO2 content as high as 63.1–63.2%, which is more conducive to improving the strength of the foamed powder.

[0047] The surface layer powder and mullite-type powder, with optimized chemical composition calculated by mass percentage, include CaO 0.9–1.0%, SiO2 64–66%, MgO 0.3–0.4%, Al2O3 19–19.5%, K2O 3.8–4.2%, and Na2O 1.6–1.8%. The SiO2 content is as high as 64–66%, and the Al2O3 content is as high as 19–19.5%, which are high-silicon and high-alumina powders, which helps to ensure the hardness and strength of the surface layer powder and mullite-type powder.

[0048] To further explain, the porous powder comprises 20-30% foamed powder and 70-80% mullite powder, calculated by mass percentage.

[0049] The limestone has a particle size of 5–7 mm.

[0050] This technical solution optimizes the addition amounts of foaming powder and mullite-type powder in the porous ceramic tile mix, which helps to achieve a porosity of 25%–35%. This allows the adhesive to penetrate the pores during installation, forming a more inlaid tenon-and-mortise structure with the tile body, ensuring a firm installation. Simultaneously, it also helps to adjust the density of the porous ceramic tile mix, ensuring its performance. It should be noted that the porosity of the ceramic tile mix is ​​calculated based on volume ratio.

[0051] Furthermore, by limiting the particle size of limestone in this technical solution, the diameter of the pores is set to 1.5–2 mm and the depth to 1.8–2 mm, which not only helps to ensure the adhesion but also helps to ensure the strength of the tiles.

[0052] To further explain, the particle size distribution of the foamed powder is as follows: by mass percentage, the residue on a 20-mesh sieve is 0.3-0.5%, the residue on a 40-mesh sieve is 1.5-2.5%, the residue on a 60-mesh sieve is 55-65%, and the residue on a 100-mesh sieve is 97.5-98.5%.

[0053] This technical solution optimizes the particle size distribution of the foaming powder. On one hand, it facilitates the formation of pores of varying sizes after calcination, increasing the irregularity and randomness of the pore structure and reducing the difficulty of preparation. It also allows the adhesive to quickly penetrate the pores from multiple directions and angles, forming a more stable interlocking tenon-and-mortise structure and improving bonding strength. On the other hand, this particle size distribution allows the bulk density of the foaming powder to reach 0.93–0.95 g / cm³. 3 This process ensures that the porous powder obtained by mixing foaming powder and mullite powder has good flowability, which is beneficial for molding and also facilitates the timely discharge of gas generated during the calcination of the porous powder to form irregular pores.

[0054] To further explain, the thickness of the porous layer is 2-3 mm, and the thickness of the surface layer is 7-8 mm.

[0055] This technical solution also optimizes the thickness of the perforated layer and the surface layer, so that the adhesive and the tile can form a stable interlocking tenon structure during installation, which further ensures the installation firmness and also helps to further ensure the strength of the tile.

[0056] Further explanation: the clay II comprises bentonite, washed kaolin, and Luoshan clay. The chemical composition of the Luoshan clay, calculated by mass percentage, includes CaO 1.2–1.3%, SiO2 68.5–68.6%, Fe2O3 3.2–3.3%, MgO 0.7–0.8%, TiO2 0.4–0.5%, Al2O3 13.9–14.0%, K2O 3.0–3.1%, and Na2O 1.1–1.3%, with the remainder being loss on ignition.

[0057] According to the mass fractions, both the surface layer powder and the mullite-type powder include 10-15 parts bentonite, 2-6 parts washed kaolin, 5-10 parts Luoshan clay, 1-3 parts calcined coal gangue, 15-18 parts green gangue, 10-16 parts recycled material, and 40-48 parts flux II.

[0058] Since bentonite, washed kaolin, and Luoshan clay are all beneficial for improving the plasticity, grouting formability, and strength of surface layer powder and mullite-type powder, this technical solution preferably uses clay II, which includes bentonite, washed kaolin, and Luoshan clay, and limits the amount of bentonite, washed kaolin, and Luoshan clay added, which is beneficial for further improving the performance of surface layer powder and mullite-type powder.

[0059] To further explain, the recycled materials include polishing mud, waste brick powder, and recycled brick blanks;

[0060] According to the mass fractions, both the surface layer powder and the mullite-type powder include 10-15 parts bentonite, 2-6 parts washed kaolin, 5-10 parts Luoshan clay, 1-3 parts calcined coal gangue, 15-18 parts green gangue, 5-7 parts polishing mud, 4-6 parts waste brick powder, 1-3 parts recycled raw material, and 40-48 parts flux II.

[0061] Polishing sludge refers to recycled materials obtained from polishing ceramic surfaces; waste brick powder refers to powdery particles obtained from waste bricks in construction waste after sorting, crushing, screening, and grinding; recycled blanks refer to blanks discarded during the initial shaping or processing of ceramics due to various reasons (such as shape not meeting requirements, surface defects, and drying cracks). All three raw materials are recycled materials in the ceramics industry and possess the characteristics of low cost and high strength. This technical solution preferentially includes polishing sludge, waste brick powder, and recycled blanks as recycled materials, and optimizes the addition amounts of these three raw materials to ensure product performance at a lower cost.

[0062] Preferably, the chemical composition of the polishing paste, calculated by mass percentage, includes CaO 1.8–1.85%, SiO2 63.4–63.5%, Fe2O3 1.15–1.20%, MgO 0.8–0.9%, TiO2 0.4–0.45%, Al2O3 20.4–20.5%, K2O 3.6–3.65%, and Na2O 1.8–1.9%, with the remainder being loss on ignition.

[0063] Preferably, the chemical composition of the waste brick powder, calculated by mass percentage, includes CaO 1.2–1.3%, SiO2 64.2–64.3%, Fe2O3 1.3–1.4%, MgO 0.3–0.4%, TiO2 0.3–0.4%, Al2O3 21.2–21.4%, K2O 4.0–4.1%, and Na2O 1.8–1.9%, with the remainder being loss on ignition.

[0064] Preferably, the chemical composition of the recycled billet, calculated by mass percentage, includes CaO 1.1–1.2%, SiO2 62.8–62.9%, Fe2O3 1.3–1.4%, MgO 0.4–0.45%, TiO2 0.4–0.45%, Al2O3 20.4–20.5%, K2O 3.8–3.9%, and Na2O 1.7–1.9%, with the remainder being loss on ignition.

[0065] Preferably, the flux II comprises potassium feldspar, sodium feldspar, and porcelain stone;

[0066] According to the mass fractions, both the surface powder and the mullite-type powder include 10-15 parts bentonite, 2-6 parts washed kaolin, 5-10 parts Luoshan clay, 1-3 parts calcined coal gangue, 15-18 parts green gangue, 5-7 parts polishing mud, 4-6 parts waste brick powder, 1-3 parts recycled raw material, 8-10 parts potassium feldspar, 27-31 parts sodium feldspar, and 5-7 parts porcelain stone.

[0067] Since potassium feldspar, sodium feldspar, and porcelain stone all have good fluxing effects, in order to reduce the firing temperature of the surface powder and mullite-type powder, this technical solution preferably uses flux II, which includes potassium feldspar, sodium feldspar, and porcelain stone, and limits the amount of potassium feldspar, sodium feldspar, and porcelain stone added to ensure the fluxing effect.

[0068] It should be noted that porcelain stone is a silicate rock mineral composed of quartz, sericite, feldspar, and aluminum oxide, etc., and its chemical composition mainly includes SiO2, Al2O3, K2O, Na2O, and Fe2O3. In this technical solution, the porcelain stone is manufactured by Yuanqu Chengtaiyuan Trading Co., Ltd., and the model is 8-potassium porcelain stone.

[0069] Preferably, by mass fraction, both the surface powder and the mullite-type powder comprise 12.5 parts bentonite, 4.0 parts washed kaolin, 7.5 parts Luoshan clay, 2.0 parts calcined coal gangue, 16.5 parts green gangue, 6.0 parts polishing mud, 5.0 parts waste brick powder, 2.0 parts recycled raw material, 9.0 parts potassium feldspar, 29.5 parts sodium feldspar, and 6.0 parts porcelain stone.

[0070] To further explain, the clay I includes Honda clay and Dajiang black clay, and the mixing ratio of Honda clay and Dajiang black clay by mass is (2-4):1.

[0071] The chemical composition of the Honda clay, calculated by mass percentage, includes CaO 0.1–0.2%, SiO2 51.7–51.8%, Fe2O3 2.7–2.8%, MgO 0.6–0.7%, TiO2 0.4–0.5%, Al2O3 0.3–30.4%, K2O 2.9–3.0%, and Na2O 0.01–0.02%, with the remainder being loss on ignition.

[0072] The chemical composition of the Dajiang black mud, calculated by mass percentage, includes CaO 0.25–0.3%, SiO2 51.5–51.6%, Fe2O3 2.5–2.6%, MgO 0.6–0.7%, TiO2 0.3–0.4%, Al2O3 31.1–31.2%, K2O 2.7–2.8%, and Na2O 0.2–0.25%, with the remainder being loss on ignition.

[0073] Both Honda clay and Dajiang black clay are beneficial for improving the plasticity, injection molding properties, and strength of foamed powder. Therefore, this technical solution preferably uses clay I, including Honda clay and Dajiang black clay, to ensure the performance of the foamed powder. Furthermore, since Honda clay has a higher silica content and a higher alumina content than Dajiang black clay, this is even more beneficial for improving the performance of the foamed powder. Therefore, this technical solution preferably uses a higher amount of Honda clay than Dajiang black clay.

[0074] Further explanation: Flux I includes nepheline, potassium feldspar, and black talc, and the foaming powder comprises the following raw materials in parts by mass: 10-12 parts clay I, 8-12 parts polishing slag, 15-20 parts limestone, 25-30 parts nepheline, 20-25 parts potassium feldspar, and 8-12 parts black talc.

[0075] Nepheline, potassium feldspar, and black talc all possess good fluxing effects. Compared to conventional potassium and sodium feldspar, nepheline has a smaller coefficient of expansion. The introduction of a large amount of nepheline can adjust the coefficient of expansion of the foaming powder, matching it with that of the mullite-type powder. This prevents cracking after the tiles are fired in the kiln, ensuring the tiles' hardness and stain resistance. Furthermore, the chemical composition of black talc is mainly silicon dioxide and magnesium oxide, which, in addition to its fluxing effect, also helps improve the strength of the foaming powder. Therefore, this technical solution preferably uses flux I, which includes nepheline, potassium feldspar, and black talc, to ensure the performance of the foaming powder.

[0076] Preferably, the foaming powder comprises, by weight, 12 parts clay I, 10 parts polishing residue, 17 parts limestone, 29 parts nepheline, 22 parts potassium feldspar, and 10 parts black talc.

[0077] A method for preparing a ceramic tile with holes on its bottom surface, comprising the following steps:

[0078] A. Mix clay I, polishing residue, limestone and flux I evenly according to the formula to obtain foaming powder;

[0079] B. Mix clay II, calcined coal gangue, green gangue, recycled material and flux II evenly according to the formula to obtain mullite-type powder;

[0080] C. After mixing the foaming powder and the mullite powder evenly according to the formula, a porous powder is obtained.

[0081] D. After spreading the porous powder, a porous layer is obtained; take mullite-type powder as the surface powder, spread the surface powder on the top of the porous layer to obtain the surface layer, and after pressing and firing in a kiln, a ceramic tile with holes at the bottom is obtained; wherein, the firing temperature is 1120~1125℃, and the firing time is 35~40min.

[0082] This technical solution also proposes a method for preparing ceramic tiles with holes on the bottom surface. The preparation method is simple and easy to operate, which helps to ensure that the water absorption rate of the ceramic tile is <0.05%, the modulus of rupture is ≥47MPa, and the breaking strength is ≥2000N. Under the premise of reducing the water absorption rate and improving the strength of the ceramic tile, the adhesion of the ceramic tile is ensured.

[0083] Furthermore, the calcination temperature is 1120–1125℃ and the calcination time is 35–40 minutes. Based on the properties of foaming powder and mullite powder, ceramic tiles can be calcined at a lower calcination temperature and shorter calcination time, achieving low-cost and green production, which is conducive to improving the competitiveness of ceramic tile products.

[0084] The technical solution of the present invention will be further illustrated below through specific embodiments.

[0085] Performance testing:

[0086] Water absorption rate: The water absorption rate was tested according to the test method in GB / T 3810.3-2016 Ceramic Tile Test Methods Part 3: Determination of water absorption rate, apparent porosity, apparent relative density and bulk density.

[0087] Modulus of rupture: The modulus of rupture was tested according to the test method in GB / T3810.7-2016 "Test methods for ceramic tiles - Part 4: Determination of modulus of rupture and breaking strength".

[0088] Destructive strength: The destructive strength was tested according to the test method in GB / T3810.7-2016 "Test methods for ceramic tiles - Part 4: Determination of modulus of rupture and destructive strength".

[0089] Adhesion firmness: After the tiles are pasted, a five-point tapping test is used, that is, tapping the four corners and the center of the tile respectively, and judging whether there is hollow sound by the change of sound. If there is no hollow sound, the adhesion firmness is qualified.

[0090] The calcined coal gangue used in the embodiments and comparative examples of the present invention was manufactured by Shandong Zibo Hengli Trading Co., Ltd., with model number 50 calcined gangue; the green gangue was manufactured by Yuanqu Chengtaiyuan Trading Co., Ltd., with model number 40 green gangue; and the porcelain stone was manufactured by Yuanqu Chengtaiyuan Trading Co., Ltd., with model number 8 potassium porcelain stone. The chemical composition of the following materials, calculated by mass percentage, is as follows: CaO 1.68%, SiO2 63.12%, Fe2O3 1.4%, MgO 0.85%, TiO2 0.4%, Al2O3 20.29%, K2O 3.76%, and Na2O 1.93%, with the remainder being loss on ignition. The chemical composition of the following materials, calculated by mass percentage, is as follows: Honda Ni 0.17%, SiO2 51.72%, Fe2O3 2.7%, MgO 0.6%, TiO2 0.49%, Al2O3 30.31%, K2O 2.99%, and Na2O 0.01%, with the remainder being loss on ignition. The chemical composition of the following materials, calculated by mass percentage, is as follows: Dajiang Heini Ni 0.28%, SiO2 51.52%, Fe2O3 2.51%, MgO 0.68%, TiO2 0.49%, Al2O3 30.31%, K2O 2.99%, and Na2O 0.01%, with the remainder being loss on ignition. The chemical composition of the following materials is as follows: 0.39% CaO, 31.19% Al2O3, 2.72% K2O, and 0.21% Na2O, with the remainder being loss on ignition; The chemical composition of the Luoshan soil includes CaO 1.24%, SiO2 68.59%, Fe2O3 3.24%, MgO 0.77%, TiO2 0.42%, Al2O3 13.99%, K2O 3.03%, and Na2O 1.2%, with the remainder being loss on ignition; The chemical composition of the polishing slurry includes CaO 1.83%, SiO2 63.49%, Fe2O3 1.19%, MgO 0.84%, TiO2 0.42%, Al2O3 20.49%, K2O 3.62%, and Na2O 1.87%, with the remainder being loss on ignition; The chemical composition of the waste brick powder, calculated by mass percentage, includes CaO... The chemical composition of the recycled billet, calculated by mass percentage, includes CaO 1.27%, SiO2 64.26%, Fe2O3 1.33%, MgO 0.36%, TiO2 0.36%, Al2O3 21.3%, K2O 4.07%, and Na2O 1.87%, with the remainder being loss on ignition. Additionally, for items not specifically described in the examples, the techniques or conditions described in the literature or the product instructions were followed. Reagents or instruments used, unless otherwise specified, are commercially available products.

[0091] Example 1

[0092] A method for preparing a ceramic tile with holes on its bottom surface includes the following steps:

[0093] A. Mix 12 parts of clay I (mixed with Honda clay and Dajiang black clay in a 3:1 ratio), 10 parts of polishing residue, 17 parts of limestone with a particle size of 5mm, 29 parts of nepheline, 22 parts of potassium feldspar, and 10 parts of black talc evenly to obtain a foaming powder with a particle size distribution of 0.3% residue on a 20-mesh sieve, 1.5% residue on a 40-mesh sieve, 60% residue on a 60-mesh sieve, and 98% residue on a 100-mesh sieve.

[0094] B. Mix 12.5 parts bentonite, 4.0 parts washed kaolin, 7.5 parts Luoshan clay, 2.0 parts calcined coal gangue, 16.5 parts green gangue, 6.0 parts polishing mud, 5.0 parts waste brick powder, 2.0 parts recycled raw material, 9.0 parts potassium feldspar, 29.5 parts sodium feldspar, and 6.0 parts porcelain stone evenly to obtain mullite-type powder.

[0095] C. According to the mass percentage, the foaming powder with a mass ratio of 30% and the mullite powder with a mass ratio of 70% are mixed evenly to obtain the porous powder.

[0096] D. After spreading the porous powder, a porous layer with a thickness of 3mm is obtained; mullite-type powder is taken as the surface powder and spread on the top of the porous layer to obtain a surface layer with a thickness of 7mm. After pressing and firing in a kiln, a ceramic tile with holes at the bottom is obtained; the firing temperature is 1120℃, the firing time is 40min, and the aluminum oxide content in the ceramic tile body is 25%.

[0097] Example 2

[0098] A method for preparing a ceramic tile with holes on its bottom surface includes the following steps:

[0099] A. Mix 10 parts of clay I (mixed with Honda clay and Dajiang black clay in a 4:1 ratio), 12 parts of polishing residue, 20 parts of limestone with a particle size of 6mm, 25 parts of nepheline, 20 parts of potassium feldspar, and 8-12 parts of black talc evenly to obtain a foaming powder with a particle size distribution of 0.5% residue on a 20-mesh sieve, 2% residue on a 40-mesh sieve, 60% residue on a 60-mesh sieve, and 97.5% residue on a 100-mesh sieve.

[0100] B. Mix 15 parts bentonite, 2 parts washed kaolin, 5 parts Luoshan soil, 3 parts calcined coal gangue, 15 parts green gangue, 6 parts polishing mud, 6 parts waste brick powder, 2 parts recycled raw material, 8 parts potassium feldspar, 27 parts sodium feldspar and 5 parts porcelain stone evenly to obtain mullite-type powder.

[0101] C. According to the mass percentage, 20% of the foaming powder and 80% of the mullite powder are mixed evenly to obtain the porous powder.

[0102] D. After spreading the porous powder, a porous layer with a thickness of 2mm is obtained; mullite-type powder is used as the surface powder, and the surface powder is spread on the top of the porous layer to obtain a surface layer with a thickness of 8mm. After pressing and firing in a kiln, a ceramic tile with holes at the bottom is obtained; the firing temperature is 1120℃, the firing time is 38min, and the aluminum oxide content in the ceramic tile body is 23.8%.

[0103] Example 3

[0104] A method for preparing a ceramic tile with holes on its bottom surface includes the following steps:

[0105] A. Mix 11 parts of clay I, 8 parts of polishing residue, 15 parts of limestone with a particle size of 7mm, 30 parts of nepheline, 25 parts of potassium feldspar, and 8 parts of black talc in a 2:1 ratio to obtain a foaming powder with a particle size distribution of 0.4% residue on a 20-mesh sieve, 2.5% residue on a 40-mesh sieve, 65% residue on a 60-mesh sieve, and 98.5% residue on a 100-mesh sieve.

[0106] B. Mix 10 parts bentonite, 6 parts washed kaolin, 10 parts Luoshan soil, 1 part calcined coal gangue, 18 parts green gangue, 5 parts polishing mud, 5 parts waste brick powder, 3 parts recycled raw material, 9 parts potassium feldspar, 30 parts sodium feldspar and 5 parts porcelain stone evenly to obtain mullite-type powder.

[0107] C. According to the mass percentage, the foaming powder with a mass percentage of 25% and the mullite powder with a mass percentage of 75% are mixed evenly to obtain the porous powder.

[0108] D. After spreading the porous powder, a porous layer with a thickness of 2.5 mm is obtained; mullite-type powder is taken as the surface powder and spread on the top of the porous layer to obtain a surface layer with a thickness of 7.5 mm. After pressing and firing in a kiln, a ceramic tile with holes at the bottom is obtained; the firing temperature is 1125℃, the firing time is 35 min, and the aluminum oxide content in the ceramic tile body is 22.6%.

[0109] Comparative Example 1

[0110] The preparation method and raw materials of Comparative Example 1 are the same as those of Example 1, except that limestone was not added to the foaming powder formulation in Comparative Example 1.

[0111] Comparative Example 2

[0112] The preparation method and raw materials of Comparative Example 2 are the same as those of Example 1. The difference is that the amount of flux I added in Comparative Example 2 is the same as that of flux II. That is, according to the mass parts, the foaming powder in Comparative Example 2 includes the following raw materials: 12 parts of clay I mixed with Honda clay and Dajiang black clay in a 3:1 ratio, 10 parts of polishing slag, 17 parts of limestone, 19 parts of nepheline, 14.5 parts of potassium feldspar and 10 parts of black talc.

[0113] Tiles were prepared using different preparation methods described in the above embodiments and comparative examples. The water absorption rate, modulus of rupture, breaking strength, and adhesive strength of the prepared tiles were tested, and the test results are shown in Table 1 below.

[0114] Table 1. Performance test results of different ceramic tiles in the examples and comparative examples.

[0115]

[0116] As can be seen from the performance test results of each embodiment in the table above, the ceramic tile prepared by the method of preparing ceramic tiles with holes on the bottom surface has a water absorption rate of <0.05%, a modulus of rupture of ≥47MPa, and a breaking strength of ≥2000N. Under the premise of reducing the water absorption rate and improving the strength of the ceramic tile, the adhesion of the ceramic tile is ensured.

[0117] Comparative Example 1 showed poor adhesion of the tiles due to the lack of limestone, resulting in a failure to meet the adhesion requirements.

[0118] In Comparative Example 2, because the amount of flux I added was the same as that of flux II (i.e., the amount of flux I was reduced), when the mullite powder began to vitrify in the liquid phase, the foamed powder was not completely melted. This was not conducive to promoting the boiling of the liquid phase of the mullite powder, thus hindering the formation of a large number of irregular pore structures. Consequently, the porosity decreased, resulting in poorer adhesion and failing to meet the adhesion requirements. Simultaneously, the reduced amount of flux I led to incomplete calcination, affecting the product's water absorption and strength.

[0119] 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 ceramic tile with holes on its bottom surface, characterized in that: The ceramic tile has a water absorption rate of <0.05%, a modulus of rupture of ≥47MPa, and a breaking strength of ≥2000N; The ceramic tile comprises a perforated layer and a surface layer arranged sequentially from bottom to top; the perforated layer is obtained by calcining perforated powder, the surface layer is obtained by calcining surface layer powder, and the content of aluminum oxide in the ceramic tile is 22% to 25% by mass percentage. The porous powder includes foamed powder and mullite-type powder; wherein, calculated by mass parts, the foamed powder includes the following raw materials: 10-12 parts of clay I, 8-12 parts of polishing slag, 15-20 parts of limestone, and 53-67 parts of flux I; the flux I includes nepheline, potassium feldspar, and black talc; According to the mass fractions, both the surface powder and the mullite-type powder include 17-31 parts of clay II, 1-3 parts of calcined coal gangue, 15-18 parts of green gangue, 10-16 parts of recycled material, and 40-48 parts of flux II; the flux II includes potassium feldspar, sodium feldspar, and porcelain stone.

2. A ceramic tile with holes on its bottom surface according to claim 1, characterized in that: The chemical composition of the polishing slag, calculated by mass percentage, includes CaO 1.6–1.7%, SiO2 63.1–63.2%, Fe2O3 1.4–1.5%, MgO 0.8–0.9%, TiO2 0.2–0.3%, Al2O3 20.2–20.3%, K2O 3.7–3.8%, and Na2O 1.9–2.0%, with the remainder being loss on ignition. The chemical composition of the surface powder and the mullite powder, calculated by mass percentage, includes CaO 0.9-1.0%, SiO2 64-66%, MgO 0.3-0.4%, Al2O3 19-19.5%, K2O 3.8-4.2%, and Na2O 1.6-1.8%, with the remainder being loss on ignition.

3. A ceramic tile with holes on its bottom surface according to claim 1, characterized in that: The porous powder comprises 20-30% foamed powder and 70-80% mullite powder, calculated by weight percentage. The limestone has a particle size of 5–7 mm.

4. A ceramic tile with holes on the bottom surface according to claim 1, characterized in that: The particle size distribution of the foamed powder is as follows: by mass percentage, the residue on a 20-mesh sieve is 0.3-0.5%, the residue on a 40-mesh sieve is 1.5-2.5%, the residue on a 60-mesh sieve is 55-65%, and the residue on a 100-mesh sieve is 97.5-98.5%.

5. A ceramic tile with holes on its bottom surface according to claim 1, characterized in that: The thickness of the porous layer is 2-3 mm, and the thickness of the surface layer is 7-8 mm.

6. A ceramic tile with holes on the bottom surface according to claim 1, characterized in that: The clay II comprises bentonite, washed kaolin, and Luoshan clay. The chemical composition of the Luoshan clay, calculated by mass percentage, includes CaO 1.2–1.3%, SiO2 68.5–68.6%, Fe2O3 3.2–3.3%, MgO 0.7–0.8%, TiO2 0.4–0.5%, Al2O3 13.9–14.0%, K2O 3.0–3.1%, and Na2O 1.1–1.3%, with the remainder being loss on ignition. According to the mass fractions, both the surface layer powder and the mullite-type powder include 10-15 parts bentonite, 2-6 parts washed kaolin, 5-10 parts Luoshan clay, 1-3 parts calcined coal gangue, 15-18 parts green gangue, 10-16 parts recycled material, and 40-48 parts flux II.

7. A ceramic tile with holes on the bottom surface according to claim 6, characterized in that: The recycled materials include polishing mud, waste brick powder, and recycled blanks; According to the mass fractions, both the surface layer powder and the mullite-type powder include 10-15 parts bentonite, 2-6 parts washed kaolin, 5-10 parts Luoshan clay, 1-3 parts calcined coal gangue, 15-18 parts green gangue, 5-7 parts polishing mud, 4-6 parts waste brick powder, 1-3 parts recycled raw material, and 40-48 parts flux II.

8. A ceramic tile with holes on the bottom surface according to claim 1, characterized in that: The clay I includes Honda clay and Dajiang black clay, and the mixing ratio of Honda clay and Dajiang black clay by mass is (2-4):

1. The chemical composition of the Honda clay, calculated by mass percentage, includes CaO 0.1–0.2%, SiO2 51.7–51.8%, Fe2O3 2.7–2.8%, MgO 0.6–0.7%, TiO2 0.4–0.5%, Al2O3 30.3–30.4%, K2O 2.9–3.0%, and Na2O 0.01–0.02%, with the remainder being loss on ignition. The chemical composition of the Dajiang black clay, calculated by mass percentage, includes CaO 0.25–0.3%, SiO2 51.5–51.6%, Fe2O3 2.5–2.6%, MgO 0.6–0.7%, TiO2 0.3–0.4%, Al2O3 31.1–31.2%, K2O 2.7–2.8%, and Na2O 0.2–0.25%, with the remainder being loss on ignition.

9. A ceramic tile with holes on its bottom surface according to claim 1, characterized in that: The flux I includes nepheline, potassium feldspar, and black talc, and the foaming powder comprises the following raw materials in parts by mass: 10-12 parts clay I, 8-12 parts polishing slag, 15-20 parts limestone, 25-30 parts nepheline, 20-25 parts potassium feldspar, and 8-12 parts black talc.

10. A method for preparing a ceramic tile with holes on its bottom surface, characterized in that: The method for preparing a ceramic tile with a perforated bottom surface as described in any one of claims 1 to 9 comprises the following steps: A. Mix clay I, polishing residue, limestone and flux I evenly according to the proportion to obtain foaming powder; B. Mix clay II, calcined coal gangue, green gangue, recycled material and flux II evenly according to the formula to obtain mullite-type powder; C. After mixing the foaming powder and the mullite powder evenly according to the formula, a porous powder is obtained. D. After spreading the porous powder, a porous layer is obtained; take mullite-type powder as the surface powder, spread the surface powder on the top of the porous layer to obtain the surface layer, and after pressing and firing in a kiln, a ceramic tile with holes at the bottom is obtained; wherein, the firing temperature is 1120~1125℃, and the firing time is 35~40min.

Images