Rock plate with super-flat fine surface and preparation method

Abstract

The invention discloses a rock plate with a super-flat fine surface and a preparation method, and relates to the technical field of rock plates. S2, batching and ball feeding; s3, homogenizing, sieving and removing iron; the mixed pug is stirred and mixed every 30 minutes for five minutes and lasts for 10 hours, the stirring speed is controlled to be 15-20 revolutions per second, the iron removal step is matched with the homogenization step, magnetic separation is carried out every 30 minutes and lasts for 10 hours; s4, preparing powder by a spray tower; s5, rolling and pressing; and S6, spraying and kiln firing: carrying out a glaze pouring process, and adding 0.85% of an acrylate leveling agent into glaze slip. According to the invention, the step of mixing, stirring and deironing is repeated for ten hours during homogenization, and 0.85% of the leveling agent is added into the glaze slip, so that the raw materials are fully homogenized, the components are more uniformly distributed, the consistency of the final product can be improved, the fluidity of the glaze slip is improved by adding 0.85% of the leveling agent into the glaze slip, and the quality of the finished product is improved. Therefore, the strength and the surface flatness of the rock plate are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of rock slabs, and in particular to a rock slab with an ultra-flat and delicate surface and a preparation method thereof. Background Art

[0002] With the continuous development of ceramic technology and the change of decoration style, modern ceramic surface decoration pays more attention to the delicate and smooth effect of the surface, and a series of ultra-flat and delicate surface products such as "velvet", "silky surface" and "delicate surface" have appeared. The production process of this kind of product is to brush the surface of the blank and then decorate the surface with glaze with strict requirements on gloss and surface smoothness, and produce it through a strict firing system;

[0003] After searching, the Chinese patent authorization announcement number CN117024117A discloses a method for preparing a ceramic rock plate with an ultra-flat and fine surface, and a ceramic rock plate, the method comprising: selecting a plastic raw material and a lean raw material, the characteristics of the plastic raw material are within a first characteristic range, and the characteristics of the lean raw material are within a second characteristic range; mixing the plastic raw material and the lean raw material according to a predetermined blank formula to form a slurry, and controlling the characteristics of the slurry to be within a third characteristic range; subjecting the slurry to centrifugal atomization granulation to obtain a powder with a particle size within a particle diameter range, the powder is a solid particle, and the characteristics of the powder are within a fourth characteristic range; processing the powder to obtain a ceramic rock plate with an ultra-flat and fine surface. The present invention controls the selection of raw materials, the formula and the properties of the slurry, and uses centrifugal atomization granulation to standardize the surface quality and particle size of the powder. Without changing the production process, a ceramic rock plate with an ultra-flat and fine surface can be prepared, thereby reducing the difficulty of production.

[0004] Although the existing rock slab raw materials undergo preliminary homogenization treatment after mining, if they are not stirred multiple times during the ball milling and stirring process, the particles in the raw materials will be unevenly distributed, and the iron impurities in the slurry cannot be effectively removed, which will cause the density of the subsequent pressed bricks to be inconsistent, and ripples will easily occur during glazing, affecting the flatness of the rock slab surface. Summary of the invention

[0005] The purpose of the present invention is to solve the problem that although the existing rock slab raw materials undergo preliminary homogenization treatment after mining, if there is no multiple stirring during the ball milling and stirring process, it will lead to uneven distribution of particles in the raw materials, and the iron impurities in the slurry cannot be effectively removed, which will make the density of the subsequent pressed bricks inconsistent, and ripples are easily generated during glazing, affecting the flatness of the rock slab surface. A rock slab with an ultra-flat and delicate surface and a preparation method are provided.

[0006] To achieve the above object, the present invention provides the following technical solutions:

[0007] The present invention is a method for preparing a rock slab with an ultra-flat and fine surface, comprising:

[0008] S1. Raw material screening, inspection and testing: Take samples of the raw materials of the rock board and analyze their chemical composition to provide accurate and effective data inspection for the production formula before entering the factory;

[0009] S2, batching into balls, grinding into powder, and ball mill material testing: the raw materials that have passed the test are batched according to the proportion and sent into the ball mill through a conveyor belt;

[0010] S3, homogenization, screening, iron removal: the ball-milled slurry is homogenized to ensure uniform mud properties, large particles are removed through mechanical or pneumatic screening equipment, and magnetic separation equipment is used to remove iron impurities in the mud;

[0011] S4, spray tower powder making: the evenly mixed mud enters the spray tower and inverted drying tower through the automatic slurry conveying system;

[0012] S5, rolling, forming, drying: The powder is transported into the press by a conveyor belt and pressed into green bodies of different sizes by a large-tonnage press. The green bodies after pressing need to be dried again in a drying kiln to reduce the moisture content to below 0.5%;

[0013] S6, spraying and kiln firing: when the moisture content of the brick body drops below 0.5%, the glazing process is carried out to evenly cover the surface of the body with glaze slurry;

[0014] S7, polishing and edging: After being fired, the rock slabs are cooled and enter the edging process. The tiles are polished on the rough polishing machine and the medium polishing machine on the conveyor belt to improve the surface gloss and overall quality.

[0015] As a further solution of the present invention: the raw materials of the rock board in S1 are 40-45% potassium-sodium feldspar, 20-25% kaolin, 20-25% quartz, 3-5% bentonite, 1-3% calcium carbonate and 0.5-1.5% talc, and secondly, 0.35% fire retardant, 0.35% waterproofing agent and 0.3% reinforcing agent are added.

[0016] The bentonite set acts as a plasticizer and binder in the production of rock slabs, which can provide better formability under high pressure while maintaining stability during the firing process.

[0017] As a further solution of the present invention: after 20 hours of tumbling friction, the ball mill speed is 76-88 rpm, and the slurry fineness reaches no more than φ0.061 mm, the slurry can be discharged. If it does not reach the process standard, it needs to be re-ground.

[0018] By controlling the rotation speed of the ball mill at 76-88 rpm, the appropriate rotation speed can ensure that the grinding balls are fully stirred in the mill to achieve efficient grinding.

[0019] As a further solution of the present invention: 0.8% of a high molecular weight hyperdispersant is added to the slurry in S3, and the raw materials are stirred evenly by homogenization to ensure the consistency of the ingredients and water content. The mixed mud is stirred and mixed for five minutes every 30 minutes for 10 hours, and the stirring speed is controlled at 15-20 rpm. The iron removal step is combined with the homogenization step, and magnetic separation is performed every 30 minutes for 10 hours. After iron removal, the powder needs to be aged for more than 12 hours.

[0020] By adding 0.8% of a high molecular weight hyperdispersant into the slurry, the fluidity and stability of the slurry can be improved. The hyperdispersant can effectively reduce the aggregation between particles, enhance the uniformity of the slurry, reduce the viscosity, and make the slurry easier to handle in subsequent processing and applications.

[0021] As a further solution of the present invention: the sieving uses a 180-250 mesh sieve, and the concentration of the mud is strictly controlled to be between 50-70% during the sieving process.

[0022] By strictly controlling the mud concentration, not only can the screening efficiency be improved and the risk of screen clogging be reduced, but the efficiency and quality of subsequent processes such as drying and firing can also be ensured.

[0023] As a further solution of the present invention: the slurry mixed evenly in S4 enters the spray drying tower through an automatic slurry feeding system, and is subjected to 1000° C. hot air exchange. The particle size after drying and dehydration is 0.05-0.06 mm in diameter, and the moisture content is reduced to 7%.

[0024] Through the spray drying process, the slurry is converted into fine particles with a diameter of about 0.05-0.06 mm. This small particle size helps to improve the uniformity and density of the subsequent molding process, and the moisture content of the particles after drying is reduced to 7%. Controlling the moisture content is the key to ensuring the quality of the green body. Too low or too high moisture content will affect the molding and firing of the green body.

[0025] As a further solution of the present invention: more than 38,000 tons are rolled into billets in S4, the temperature inside the drying kiln is controlled at 60-80°C, the running direction of the circulating fan is reversed every 2 hours to ensure smooth air circulation, and iron removal and magnetic separation are performed again after powder making to ensure the quality of the powder.

[0026] The formed green body needs to be dried in a drying kiln to remove the remaining moisture. The temperature inside the drying kiln is controlled between 60-80°C. This temperature range is sufficient to effectively remove moisture without causing thermal damage to the green body. The direction of the circulating fan is reversed every 2 hours. This ensures smooth air circulation and avoids local overheating or excessive humidity, thereby ensuring the drying quality of the green body.

[0027] As a further solution of the present invention: when the moisture content of the green body reaches below 0.5%, the glaze slurry flows out from the flat gap of the glazing device through the conveyor belt to form a glaze curtain, so that the green body is glazed with a layer of glaze when passing through, and dried for 20-40 minutes, and 0.85% of acrylic ester leveling agent is added to the glaze slurry;

[0028] During the kiln firing, the bricks first slowly pass through the preheating zone for 30 minutes, and the temperature gradually rises from room temperature to 450°C to exclude free water and adsorbed water. After entering the medium and high temperature zone, the temperature ranges from 450°C to 1300°C. After reaching the highest firing temperature, the bricks enter the high insulation zone and remain there for 80 minutes to increase the liquid phase volume and new crystals to grow, ensuring complete vitrification. After passing through the insulation zone for 10 minutes, the bricks enter three cooling zones of rapid cooling, slow cooling and strong cooling, and gradually and slowly cool down to room temperature.

[0029] By adding acrylic leveling agent, the viscosity of the glaze slurry can be reduced, making it easier to flow and apply. This helps the glaze slurry to cover the surface of the blank more evenly during the glazing process and improve the flatness of the rock slab surface.

[0030] As a further solution of the present invention: after sintering and cooling in S7, the rock plate is subjected to rough polishing, medium polishing and fine polishing. After polishing, a layer of nano antifouling agent is evenly coated on the surface of the rock plate to form a protective layer, and finally the edges are ground and chamfered.

[0031] Through these fine processing steps, we can ensure that the stone slab products not only meet high standards in performance, but also meet the needs of consumers in appearance.

[0032] Compared with the prior art, the present invention has the following beneficial effects:

[0033] By repeating the mixing and stirring iron removal steps for ten hours during homogenization and adding 0.85% of leveling agent in the glaze slurry, it helps to fully homogenize the raw materials, make the distribution of each component more even, and improve the consistency of the final product. Adding 0.85% of leveling agent to the glaze slurry can improve the fluidity of the glaze slurry, making it smoother and more even when applied, reducing uneven coating thickness and dripping, which helps to improve surface smoothness and enhance the appearance quality of the rock slab. Homogenization and effective iron removal can reduce defects such as pores and cracks that may occur during the firing process, thereby improving the strength and surface flatness of the rock slab. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 The present invention is a flow chart of a method for preparing a rock slab having an ultra-flat and smooth surface. DETAILED DESCRIPTION

[0035] In order to make the technical problems, technical solutions and advantages to be solved by the present invention more clear, a detailed description will be given below with reference to the accompanying drawings and specific embodiments.

[0036] See also Figure 1 In an embodiment of the present invention, a method for preparing a rock plate with an ultra-flat and smooth surface comprises the following steps:

[0037] S1. Raw material screening, inspection and testing: Take samples of the raw materials of the rock board and analyze their chemical composition to provide accurate and effective data inspection for the production formula before entering the factory;

[0038] As a further embodiment, the raw materials of the rock board in S1 are 40-45% potassium-sodium feldspar, 20-25% kaolin, 20-25% quartz, 3-5% bentonite, 1-3% calcium carbonate and 0.5-1.5% talc, and secondly, 0.35% fire retardant, 0.35% waterproofing agent and 0.3% reinforcing agent are added;

[0039] S2, batching into balls, grinding into powder, and ball mill material testing: the raw materials that have passed the test are batched according to the proportion and sent into the ball mill through a conveyor belt;

[0040] As a further embodiment, after 20 hours of tumbling friction, the ball milling speed is 76-88 rpm, and the slurry fineness reaches no more than φ0.061 mm, the slurry can be discharged, and those that do not meet the process standards must be re-ground;

[0041] S3, homogenization, screening, iron removal: the ball-milled slurry is homogenized to ensure uniform mud properties, large particles are removed through mechanical or pneumatic screening equipment, and magnetic separation equipment is used to remove iron impurities in the mud;

[0042] As a further implementation method, 0.8% of a polymer hyperdispersant is added to the slurry in S3, and the raw materials are stirred evenly by homogenization to ensure the consistency of the ingredients and water content. The mixed slurry is stirred and mixed for five minutes every 30 minutes for 10 hours, and the stirring speed is controlled at 15-20 rpm. The iron removal step is combined with the homogenization step, and magnetic separation is performed every 30 minutes for 10 hours. After iron removal, the powder needs to be aged for more than 12 hours.

[0043] S4, spray tower powder making: the evenly mixed mud enters the spray tower and inverted drying tower through the automatic slurry conveying system;

[0044] As a further embodiment, the slurry mixed evenly in S4 enters the spray drying tower through an automatic slurry delivery system, and is subjected to hot air exchange at 1000°C. The particle size after drying and dehydration is 0.05-0.06 mm in diameter, and the moisture content is reduced to 7%;

[0045] S5, rolling, forming, drying: The powder is transported into the press by a conveyor belt and pressed into green bodies of different sizes by a large-tonnage press. The green bodies after pressing need to be dried again in a drying kiln to reduce the moisture content to below 0.5%;

[0046] As a further embodiment, when the moisture content of the green body reaches below 0.5%, the glaze slurry flows out from the flat gap of the glazing device through the conveyor belt to form a glaze curtain, so that the green body is glazed with a layer of glaze when passing through, and dried for 20-40 minutes. 0.85% acrylic leveling agent is added to the glaze slurry;

[0047] S6, spraying and kiln firing: when the moisture content of the brick body drops below 0.5%, the glazing process is carried out to evenly cover the surface of the body with glaze slurry;

[0048] As a further embodiment, when the moisture content of the green body reaches below 0.5%, the glaze slurry flows out from the flat gap of the glazing device through the conveyor belt to form a glaze curtain, so that the green body is glazed with a layer of glaze when passing through, and dried for 20-40 minutes. 0.85% acrylic leveling agent is added to the glaze slurry;

[0049] S7, polishing and edge grinding: After the fired rock slab is cooled, it enters the edge grinding process. The tiles enter the rough polishing machine and medium polishing machine on the conveyor belt for polishing to improve the surface gloss and overall quality;

[0050] As a further implementation method, after sintering and cooling in S7, the rock slab is subjected to rough polishing, medium polishing and fine polishing. After polishing, a layer of nano antifouling agent is evenly coated on the surface of the rock slab to form a protective layer, and finally the edges are ground and chamfered.

[0051] Example 1

[0052] The present invention provides a method for preparing a rock plate with an ultra-flat and smooth surface, comprising the following steps:

[0053] S1. Raw material screening, inspection and testing: Take samples of the raw materials of the rock board and analyze their chemical composition to provide accurate and effective data inspection for the production formula before entering the factory;

[0054] S2, batching into balls, grinding into powder, and ball mill material testing: the raw materials that have passed the test are batched according to the proportion and sent into the ball mill through a conveyor belt;

[0055] S3, homogenization, screening, iron removal: the ball-milled slurry is homogenized to ensure uniform mud properties, large particles are removed through mechanical or pneumatic screening equipment, and magnetic separation equipment is used to remove iron impurities in the mud;

[0056] S4, spray tower powder making: the evenly mixed mud enters the spray tower and inverted drying tower through the automatic slurry conveying system;

[0057] S5, rolling, forming, drying: The powder is transported into the press by a conveyor belt and pressed into green bodies of different sizes by a large-tonnage press. The green bodies after pressing need to be dried again in a drying kiln to reduce the moisture content to below 0.5%;

[0058] S6, spraying and kiln firing: when the moisture content of the brick body drops below 0.5%, the glazing process is carried out to evenly cover the surface of the body with glaze slurry;

[0059] S7, polishing and edge grinding: After the fired rock slab is cooled, it enters the edge grinding process. The tiles enter the rough polishing machine and medium polishing machine on the conveyor belt for polishing to improve the surface gloss and overall quality;

[0060] In S3, 0.8% of a high molecular weight hyperdispersant is added to the slurry, and the raw materials are stirred evenly by homogenization to ensure the consistency of the ingredients and water content. The mixed slurry is stirred and mixed for five minutes every 30 minutes for 10 hours, and the stirring speed is controlled at 15-20 rpm. The iron removal step is combined with the homogenization step, and magnetic separation is performed every 30 minutes for 10 hours.

[0061] In S6, 0.85% of acrylate leveling agent was added to the glaze slurry;

[0062] After testing, the Ra value of the rock slab sample reached 0.76 microns and the Rz value reached 4.4 microns.

[0063] Example 2

[0064] The method for preparing the rock plate provided in this embodiment 2 is basically the same as that in embodiment 1, except that:

[0065] In the step of homogenization, screening and iron removal in S3, 0.8% of a high molecular weight superdispersant is added to the slurry, and the raw materials are stirred evenly by homogenization to ensure the consistency of the ingredients and water content. The mixed slurry is stirred and mixed for five minutes every 30 minutes for 10 hours, and the stirring speed is controlled at 15-20 rpm. The iron removal step is combined with the homogenization step, and magnetic separation is performed every 30 minutes for 10 hours.

[0066] Meanwhile, no 0.85% acrylate leveling agent was added to the glaze slurry of S6;

[0067] After testing, the Ra value of the rock slab sample was 2.8 microns and the Rz value was 6.1 microns.

[0068] Example 3

[0069] The method for preparing the rock plate provided in this embodiment 3 is basically the same as that in embodiment 1, except that:

[0070] In the homogenization, screening and iron removal steps of S3, the mixed iron removal process method of the steps in S3 is not used;

[0071] At the same time, 0.85% of acrylic leveling agent was added to the glaze slurry of S6;

[0072] After testing, the Ra value of the rock slab sample was 3.4 microns and the Rz value was 8.9 microns.

[0073] Example 4

[0074] The method for preparing the rock plate provided in this embodiment 4 is basically the same as that in embodiment 1, except that:

[0075] In the homogenization, screening and iron removal steps of S3, the mixed iron removal process method of the steps in S3 is not used;

[0076] Meanwhile, no 0.85% acrylate leveling agent was added to the glaze slurry of S6;

[0077] After testing, the Ra value of the rock plate sample was 5 microns and the Rz value was 10.2 microns.

[0078] The Ra parameter value and Rz parameter value of the surface roughness of the ceramic rock board produced by traditional building ceramic powder and the ultra-flat and fine surface ceramic rock board prepared in the embodiment of the present application are compared as follows:

[0079] Ra R Embodiment 1 0.76 micron 4.4 microns Embodiment 2 2.8 microns 6.1 microns Embodiment 3 3.4 microns 8.9 microns Embodiment 4 5 microns 10.2 microns

[0080] From the Ra and Rz values ​​in the above table, it can be seen that for the rock slabs prepared in Examples 1-4, in S3, 0.8% of a polymer type superdispersant is added to the slurry, and the raw materials are stirred evenly by homogenization to ensure the consistency of the ingredients and water content. The mixed mud is stirred and mixed for five minutes every 30 minutes for 10 hours, and the stirring speed is controlled at 15-20 rpm. The iron removal step is combined with the homogenization step, and magnetic separation is performed every 30 minutes for 10 hours. At the same time, in S6, 0.85% of an acrylic leveling agent is added to the glaze slurry to improve the smoothness and flatness of the rock slab surface.

[0081] What is described above is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. A method for preparing a rock slab with an ultra-flat and fine surface, characterized in that: include: S1. Raw material screening, inspection and testing: Take samples of the raw materials of the rock board and analyze their chemical composition to provide accurate and effective data inspection for the production formula before entering the factory; S2, batching into balls, grinding into powder, and ball mill material testing: the raw materials that have passed the test are batched according to the proportion and sent into the ball mill through a conveyor belt; S3, homogenization, screening, iron removal: the ball-milled slurry is homogenized to ensure uniform mud properties, large particles are removed through mechanical or pneumatic screening equipment, and magnetic separation equipment is used to remove iron impurities in the mud; S4, spray tower powder making: the evenly mixed mud enters the spray tower and inverted drying tower through the automatic slurry conveying system; S5, rolling, forming, drying: The powder is transported into the press by a conveyor belt and pressed into green bodies of different sizes by a large-tonnage press. The green bodies after pressing need to be dried again in a drying kiln to reduce the moisture content to below 0.5%; S6, spraying and kiln firing: when the moisture content of the brick body drops below 0.5%, the glazing process is carried out to evenly cover the surface of the body with glaze slurry; S7, polishing and edging: After being fired, the rock slabs are cooled and enter the edging process. The tiles are polished on the rough polishing machine and the medium polishing machine on the conveyor belt to improve the surface gloss and overall quality.

2. The method for preparing a rock slab with an ultra-flat and fine surface according to claim 1, characterized in that: The raw materials of S1 medium rock board are 40-45% potassium-sodium feldspar, 20-25% kaolin, 20-25% quartz, 3-5% bentonite, 1-3% calcium carbonate and 0.5-1.5% talc. Secondly, 0.35% fire retardant, 0.35% waterproofing agent and 0.3% reinforcing agent are added.

3. The method for preparing a rock slab with an ultra-flat and fine surface according to claim 1, characterized in that: After 20 hours of tumbling and friction, the ball mill speed in S2 is 76-88 rpm. When the slurry fineness reaches no more than φ0.061 mm, the slurry can be discharged. If it does not meet the process standards, it must be ground again.

4. The method for preparing a rock slab with an ultra-flat and fine surface according to claim 1, characterized in that: 0.8% of high molecular weight hyperdispersant is added to the slurry in S3, and the raw materials are stirred evenly by homogenization to ensure the consistency of ingredients and water content. The mixed mud is stirred and mixed for five minutes every 30 minutes for 10 hours, and the stirring speed is controlled at 15-20 rpm. The iron removal step is combined with the homogenization step, and magnetic separation is performed every 30 minutes for 10 hours. After iron removal, the powder needs to be aged for more than 12 hours.

5. The method for preparing a rock slab with an ultra-flat and fine surface according to claim 1, characterized in that: The sieving is performed using a 180-250 mesh sieve, and the concentration of the mud is strictly controlled to be between 50-70% during the sieving process.

6. The method for preparing a rock slab with an ultra-flat and fine surface according to claim 1, characterized in that: The slurry mixed evenly in S4 enters the spray drying tower through an automatic slurry delivery system, and is exchanged with hot air at 1000°C. The particle size after drying and dehydration is 0.05-0.06 mm in diameter, and the moisture content is reduced to 7%.

7. The method for preparing a rock slab with an ultra-flat and fine surface according to claim 1, characterized in that: More than 38,000 tons of rolled billets are formed in S4. The temperature inside the drying kiln is controlled at 60-80°C. The direction of the circulating fan is reversed every 2 hours to ensure smooth air circulation. After powder making, iron removal and magnetic separation are carried out again to ensure the quality of the powder.

8. The method for preparing a rock slab with an ultra-flat and fine surface according to claim 1, characterized in that: When the moisture content of the green body is below 0.5%, the glaze slurry flows out from the flat gap of the glazing device through the conveyor belt to form a glaze curtain, so that the green body is glazed with a layer of glaze when passing through. It is dried for 20-40 minutes. 0.85% acrylic leveling agent is added to the glaze slurry. During the kiln firing, the bricks first slowly pass through the preheating zone for 30 minutes, and the temperature gradually rises from room temperature to 450°C to exclude free water and adsorbed water. After entering the medium and high temperature zone, the temperature ranges from 450°C to 1300°C. After reaching the highest firing temperature, the bricks enter the high insulation zone and remain there for 80 minutes to increase the liquid phase volume and new crystals to grow, ensuring complete vitrification. After passing through the insulation zone for 10 minutes, the bricks enter three cooling zones of rapid cooling, slow cooling and strong cooling, and gradually and slowly cool down to room temperature.

9. The method for preparing a rock slab with an ultra-flat and fine surface according to claim 1, characterized in that: After sintering and cooling in S7, the rock slab undergoes rough polishing, medium polishing and fine polishing. After polishing, a layer of nano antifouling agent is evenly applied on the surface of the rock slab to form a protective layer, and finally the edges are ground and chamfered.

10. A rock board with an ultra-flat and fine surface, characterized in that: The rock slab is prepared by the method for preparing a rock slab with an ultra-flat and fine surface as described in any one of claims 1 to 9.

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