Preparation method of ceramic tile with double layers of engobe and ceramic tile

Abstract

The invention provides a preparation method of a ceramic tile with double layers of engobe and the ceramic tile. The preparation method of the ceramic tile with the double layers of engobe comprises the steps that first engobe is prepared according to a first engobe raw material formula, and second engobe is prepared according to a second engobe raw material formula; applying the first engobe to a pre-prepared ceramic body to obtain a first engobe layer; the second engobe is applied to the ceramic body to which the first engobe layer is applied, and a second engobe layer is obtained; and treating the ceramic green body applied with the first engobe layer and the second engobe layer to obtain the ceramic tile. According to the preparation method, two kinds of engobe slurry are prepared, and a one-time glaze pouring process of engobe is adjusted into a two-time thin glaze layer pouring process, so that the problem of glaze pouring'orange peel 'is solved, the glaze pouring flatness is improved, the zirconium silicate content in the whole glaze is reduced, and the production cost is reduced.

Description

Technical Field

[0001] The invention relates to the technical field of ceramic production, and in particular to a preparation method of a ceramic tile with double-layer cosmetic soil and the ceramic tile. Background Art

[0002] In recent years, the ceramic industry has to improve product quality on the one hand and reduce production costs on the other. The popular products such as "golden velvet" and "fine glaze" have high requirements for the flatness of the glaze surface. In order to meet the flatness requirements, some production lines add a polishing process before applying the makeup soil, that is, the surface of the dried body is polished. However, there are two problems with the use of the polishing process. The first is that it is easy to generate dust, which is not conducive to the control of the on-site environment; the second is that as the concentration of dust in the polishing equipment increases, fine powder accumulates on the polishing grinding block. If it is not cleaned in time, it will damage the surface of the body, resulting in the generation of glaze pinholes. In addition, for fully polished glaze products, the flatness of the glaze after firing is directly related to the polishing quality and polishing efficiency. The better the glaze flatness, the lower the incidence of defects such as polished pockmarks; at the same time, the better the glaze flatness, the more conducive it is to the polishing process to improve the polishing speed and efficiency.

[0003] At present, the process of glazed tiles is generally to apply a layer of cosmetic soil on the blank surface first, then inkjet print for pattern decoration, and finally apply a layer of transparent glaze. The whiteness of the cosmetic soil plays a key role in the expression of pattern texture, especially for imitation marble products. The whiteness of the cosmetic soil is one of the key factors in the expression of its texture details. The higher the whiteness of the cosmetic soil, the clearer the texture details are expressed, and the closer it is to the stone texture. However, considering the cost, the whiteness of the blank is currently controlled at 20-30 degrees. To make the whiteness of the semi-finished product after applying the cosmetic soil above 60 degrees, the cosmetic soil is required to have a stronger covering ability on the blank. To improve the covering ability of the cosmetic soil on the blank, one way is to increase the content of the opacifier zirconium silicate in the formula, but zirconium silicate is expensive, so it increases the cost; another way is to increase the thickness of the cosmetic soil without changing the formula, but when a thicker cosmetic soil glaze slurry is applied, its water absorption rate is slow, which is easy to produce the "orange peel" phenomenon of the glaze surface, affecting the flatness after glazing.

[0004] Therefore, the prior art has defects and needs to be improved and developed. Summary of the invention

[0005] The technical problem to be solved by the present invention is that, in view of the above-mentioned defects of the prior art, a method for preparing a ceramic tile with a double layer of cosmetic soil and a ceramic tile are provided, aiming to solve the problem in the prior art that in order to improve the covering ability of the cosmetic soil on the blank, some methods will increase the cost, and some methods will affect the flatness after glazing.

[0006] The technical solution adopted by the present invention to solve the technical problem is as follows:

[0007] The first embodiment of the present application provides a method for preparing a ceramic tile with a double-layer cosmetic soil, which comprises:

[0008] A first cosmetic soil is prepared according to the first cosmetic soil raw material formula, and a second cosmetic soil is prepared according to the second cosmetic soil raw material formula;

[0009] Applying the first cosmetic soil on the pre-prepared ceramic body to obtain a first cosmetic soil layer;

[0010] Applying the second cosmetic soil on the ceramic body to which the first cosmetic soil layer has been applied, to obtain a second cosmetic soil layer;

[0011] The ceramic body with the first makeup soil layer and the second makeup soil layer applied thereto is processed to obtain a ceramic tile.

[0012] According to the above-mentioned technical means, the embodiment of the present application prepares two kinds of cosmetic soil slurries so as to adjust the one-time cosmetic soil glazing process to a two-time thin glazing process, thereby solving the "orange peel" problem of glazing and improving the smoothness of glazing; and reducing the zirconium silicate content in the overall glaze, thereby reducing production costs.

[0013] In one embodiment of the present application, the first cosmetic soil raw material formula is different from the second cosmetic soil raw material formula, the first cosmetic soil is a high ball clay, high tailings, zirconium-free formula system cosmetic soil, and the second cosmetic soil is a high pyroxene formula system cosmetic soil.

[0014] According to the above technical means, two kinds of cosmetic soil slurries are prepared in the embodiment of the present application to improve the smoothness of the glaze.

[0015] In one embodiment of the present application, the weight content of kaolin in the first cosmetic soil raw material formula is ≥20%, the weight content of industrial tailings sand is ≥60%, and the weight content of zirconium-containing material is 0; the weight content of nepheline in the second cosmetic soil raw material formula is ≥40%, and the raw materials of the first cosmetic soil formula include: potassium feldspar, burned talc, kaolin and industrial tailings sand.

[0016] According to the above-mentioned technical means, in order to further reduce the formula cost, the embodiment of the present application introduces industrial tailings into the first cosmetic soil raw material formula without zirconium-containing raw materials, thereby reducing the glaze cost while ensuring the product brick shape, whiteness and other indicators.

[0017] In one embodiment of the present application, the raw materials in the first cosmetic soil raw material formula include, by weight:

[0018] 4-6 parts of potassium feldspar, 5-7 parts of calcined talc, 20-27 parts of kaolin, 60-70 parts of industrial tailings sand;

[0019] The raw materials in the second cosmetic soil raw material formula include, by weight:

[0020] 8-10 parts of potassium feldspar, 10-18 parts of zirconium silicate, 1-3 parts of calcined talc, 10-15 parts of quartz, 5-10 parts of wollastonite, 8-10 parts of kaolin, 0-3 parts of aluminum oxide, and 40-45 parts of nepheline.

[0021] According to the above-mentioned technical means, the embodiment of the present application recycles and utilizes cheap industrial tailings sand raw materials, which have a high sintering temperature. By adjusting the sintering degree of the formula by fluxes such as talc, the amount of industrial tailings sand can reach 70%, thereby reducing the formula cost. At the same time, it turns waste into treasure and reduces the environmental pollution caused by tailings landfill, which has good economy and environmental protection.

[0022] In one embodiment of the present application, the chemical components of the first cosmetic soil raw material formula, calculated by mass percentage, include:

[0023] Loss on ignition 2%~4%, SiO2 68%~72%, Al2O3 16%~18%, Fe2O3 0~0.3%, CaO0~1%, MgO 2%~3%, K2O 2%~3%, Na2O 3%~4%;

[0024] The chemical components of the second cosmetic soil raw material formula, calculated by mass percentage, include:

[0025] Loss on ignition 3%~4%, SiO2 52%~60%, Al2O3 15%~20%, Fe2O3 0~0.25%, CaO 3%~5%, MgO 1%~1.5%, K2O 2%~3%, Na2O 4%~5%, ZrO2 7%~10%.

[0026] According to the above-mentioned technical means, the first cosmetic soil raw material formula provided in the embodiment of the present application brings many benefits such as improving physical properties, optimizing chemical stability, improving process performance, environmental protection and sustainability.

[0027] In one embodiment of the present application, the whiteness value of the single raw material in the first cosmetic soil raw material formula after sintering is 68-70 degrees, and the glaze amount of the first cosmetic soil is 295-310g / m 2 The whiteness value of the first cosmetic soil layer is 40-50 degrees, the thickness of the first cosmetic soil layer is 0.08-0.1 mm, and the glossiness of the first cosmetic soil layer after sintering is 3.5-5 degrees; the glaze amount of the second cosmetic soil is 360-380 g / m 2The whiteness value of the second cosmetic soil layer is 50 to 60 degrees, the thickness of the second cosmetic soil layer is 0.12 to 0.15 mm, the glossiness of the second cosmetic soil layer after sintering is 4 to 6 degrees, the whiteness value of the first cosmetic soil layer and the second cosmetic soil layer after superposition is 66 to 76 degrees, the thickness of the first cosmetic soil layer and the second cosmetic soil layer after superposition is 0.2 to 0.25 mm, and the glossiness of the first cosmetic soil layer and the second cosmetic soil layer after superposition is 4 to 6 degrees.

[0028] According to the above technical means, the embodiment of the present application can ensure that a cosmetic soil layer with better flatness and whiteness is obtained.

[0029] In one embodiment of the present application, the first cosmetic soil is prepared according to the first cosmetic soil raw material formula, and the second cosmetic soil is prepared according to the second cosmetic soil raw material formula, including:

[0030] According to the first cosmetic soil raw material formula, each raw material is put into a ball mill, and water is added to grind for 4 to 6 hours, and after iron removal, sieving, and aging, the first cosmetic soil is obtained;

[0031] The first cosmetic soil has a fineness of 0.4% to 0.6% of the residue on a 325-mesh sieve, a specific gravity of 1.70 to 1.75, and an Engler viscosity of 33 to 36S;

[0032] According to the second cosmetic soil raw material formula, each raw material is put into a ball mill, and water is added to grind for 5 to 6 hours, and after iron removal, sieving, and aging, the second cosmetic soil is obtained;

[0033] The second cosmetic soil has a fineness of 0.4% to 0.5% of the residue on a 325-mesh sieve, a specific gravity of 1.78 to 1.82, and an Engler viscosity of 28 to 32S.

[0034] In one embodiment of the present application, the temperature of the ceramic body is 80-90°C, the brick moving speed of the ceramic body between applying the first cosmetic soil and the second cosmetic soil is 50m / min, and the distance from the first cosmetic soil glazing position to the second cosmetic soil glazing position is 12-18m.

[0035] According to the above technical means, when applying the second makeup soil, there is no obvious trace of moisture on the surface of the brick blank when viewed from the side, which can ensure that the moisture of the first makeup soil has been basically evaporated and absorbed by the blank and the blank maintains a certain degree of wetness. This can avoid the situation where the distance is too short and the moisture of the first makeup soil on the brick blank has not been completely evaporated and absorbed, and the second makeup soil is directly applied, causing orange peel defects in the product. This can also avoid the situation where the distance is too long and the first makeup soil has been completely dry, the surface of the blank is too dry, the wetness is insufficient, and pinhole defects are prone to occur.

[0036] In one embodiment of the present application, a ceramic body with a first cosmetic soil layer and a second cosmetic soil layer applied thereto is processed to obtain a ceramic tile, comprising:

[0037] Performing pattern decoration on the ceramic body provided with the first cosmetic soil layer and the second cosmetic soil layer to obtain a decorated body;

[0038] After transparent glaze is applied on the surface of the decorated body, it is put into a kiln for high-temperature firing to obtain a ceramic tile.

[0039] According to the above-mentioned technical means, the embodiment of the present application divides the conventional one-layer cosmetic soil layer for producing ceramic tile products in the industry into two layers, which are applied in small amounts multiple times, reducing the amount of glaze applied each time, making the green body easier to absorb, and the glaze layer is smoother after the double layers of cosmetic soil are superimposed, thereby improving the production quality of the product, and avoiding the use of a large amount of cosmetic soil applied at one time, a thick glaze layer, and slow water absorption of the glaze slurry, which leads to the occurrence of orange peel phenomenon; and the first layer of cosmetic soil is a high-ball clay, high-tailings, zirconium-free formula system cosmetic soil, which can consume a large amount of industrial tailings sand and reduce the use of expensive zirconium silicate raw materials. Multiple measures are taken to greatly reduce production costs.

[0040] A second aspect of the present application provides a ceramic tile, wherein the ceramic tile is prepared by the preparation method of the ceramic tile with a double-layer cosmetic soil as described above.

[0041] The present invention achieves the following beneficial effects:

[0042] First, the embodiment of the present application digests cheap industrial tailings sand raw materials, which have a high sintering temperature. By adjusting the sintering degree of the formula by fluxes such as talc, the amount of industrial tailings can reach 70%, reducing the cost of the formula, while turning waste into treasure and reducing environmental pollution caused by tailings landfill, with good economy and environmental protection.

[0043] Second, the embodiment of the present application innovates the glazing process of cosmetic soil, changing from pouring a thick glaze once to pouring a thin glaze twice. Since the water content of the glaze slurry is relatively high, when the cosmetic soil layer is applied as a thick glaze, its water absorption rate is relatively slow, which is easy to produce the "orange peel" phenomenon of the glaze surface, affecting the flatness of the product after pouring the glaze. When it is changed to pouring two thinner glazes, the first thinner cosmetic soil can quickly absorb water and form a water molecule channel after application, and the second thinner cosmetic soil can also quickly absorb water after being applied on its surface, ensuring the flatness of the glazing, so the glazing flatness is better after changing to two glazings.

[0044] Third, the overall glazing amount of the cosmetic soil in the embodiment of the present application is increased, and the flatness is improved, which is more conducive to controlling the brick shape deformation of the glazed bricks, and also provides a basis for reducing the glazing amount for transparent glazes with a smaller expansion coefficient.

[0045] Fourth, in addition to the economic benefits, the embodiment of the present application also effectively improves the flatness of the glaze surface, which has a positive effect on improving product quality and improving the efficiency of the polishing process. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] Figure 1 It is a flow chart of a preferred embodiment of a method for preparing a ceramic tile with a double-layer cosmetic soil in the present invention.

[0047] Figure 2 It is a specific process flowchart of a preferred embodiment of a method for preparing a ceramic tile with a double-layer cosmetic soil in the present invention. DETAILED DESCRIPTION

[0048] In order to make the purpose, technical solution and advantages of the present invention clearer and more specific, the present invention is further described in detail below with reference to the accompanying drawings and examples. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0049] Makeup clay can cover the roughness, unevenness and darker areas on the surface of ceramic bodies, making the surface of ceramic products smoother, flatter and more beautiful. The use of makeup clay can make the upper glaze appear more vivid, and at the same time it is easy to color, improving the decorative effect of ceramic products; moreover, makeup clay can improve the quality of the glaze surface, making the glaze layer look beautiful, bright, soft and moist.

[0050] See also Figure 1 , Figure 1 1 is a flow chart of the method for preparing a ceramic tile having a double-layer cosmetic soil in the present invention. Figure 1 As shown, the method for preparing a ceramic tile with a double-layer cosmetic soil according to an embodiment of the present invention comprises the following steps:

[0051] Step S100: preparing a first cosmetic soil according to a first cosmetic soil raw material formula, and preparing a second cosmetic soil according to a second cosmetic soil raw material formula.

[0052] In an embodiment of the present application, the first cosmetic soil raw material formula is different from the second cosmetic soil raw material formula, the first cosmetic soil is a high ball clay, high tailings, zirconium-free formula system cosmetic soil, the second cosmetic soil is a high pyroxene formula system cosmetic soil, and can also be a conventional cosmetic soil formula.

[0053] Specifically, from the perspective of ensuring the color development effect of printing ink, the formula of the second makeup soil (i.e., the makeup soil in direct contact with the inkjet ink) remains unchanged; from the perspective of cost and whiteness, the first makeup soil can remove the expensive zirconium silicate, and raw materials with higher whiteness are preferred. The two makeup soils are ball-milled, iron-removed, sieved, and aged according to the formula to obtain qualified makeup soil glaze slurry.

[0054] The embodiment of the present application prepares two kinds of cosmetic clay slurries to adjust the one-time cosmetic clay glazing process to a two-time thin glazing process, thereby solving the "orange peel" problem of glazing and improving the smoothness of glazing; and reducing the zirconium silicate content in the overall glaze, thereby reducing production costs.

[0055] In an embodiment of the present application, the weight content of kaolin in the first cosmetic soil raw material formula is ≥20%, the weight content of industrial tailings sand is ≥60%, and the weight content of zirconium-containing material is 0; the weight content of nepheline in the second cosmetic soil raw material formula is ≥40%, and the raw materials of the first cosmetic soil formula include: potassium feldspar, burned talc, kaolin and industrial tailings sand.

[0056] In one embodiment of the present application, the raw materials in the first cosmetic soil raw material formula include, by weight: 4-6 parts of potassium feldspar, 5-7 parts of calcined talc, 20-27 parts of kaolin, and 60-70 parts of industrial tailings sand; the raw materials in the second cosmetic soil raw material formula include, by weight:

[0057] 8-10 parts of potassium feldspar, 10-18 parts of zirconium silicate, 1-3 parts of calcined talc, 10-15 parts of quartz, 5-10 parts of wollastonite, 8-10 parts of kaolin, 0-3 parts of aluminum oxide, and 40-45 parts of nepheline.

[0058] The embodiment of the present application recycles and utilizes cheap industrial tailings sand raw materials, which have a high sintering temperature. By adjusting the sintering degree of the formula through fluxes such as talc, the amount of industrial tailings sand can reach 70%, thereby reducing the cost of the formula, turning waste into treasure, and reducing environmental pollution caused by tailings landfill, with good economy and environmental protection.

[0059] In one embodiment of the present application, the chemical components of the first cosmetic soil raw material formula, measured by mass percentage, include: loss on ignition 2% to 4%, SiO2 68% to 72%, Al2O3 16% to 18%, Fe2O3 0 to 0.3%, CaO 0 to 1%, MgO 2% to 3%, K2O 2% to 3%, and Na2O 3% to 4%; the chemical components of the second cosmetic soil raw material formula, measured by mass percentage, include: loss on ignition 3% to 4%, SiO2 52% to 60%, Al2O3 15% to 20%, Fe2O3 0 to 0.25%, CaO 3% to 5%, MgO 1% to 1.5%, K2O 2% to 3%, Na2O 4% to 5%, and ZrO2 7% to 10%.

[0060] The first cosmetic soil raw material formula provided in the embodiment of the present application brings many benefits such as improving physical properties, optimizing chemical stability, improving process performance, and environmental protection and sustainability.

[0061] In the embodiment of the present application, the whiteness value of the single raw material in the first cosmetic soil raw material formula after sintering is 68-70 degrees, and the glaze amount of the first cosmetic soil is 295-310g / m 2The whiteness value of the first cosmetic soil layer is 40-50 degrees, the thickness of the first cosmetic soil layer is 0.08-0.1 mm, the glossiness of the first cosmetic soil layer after sintering is 3.5-5 degrees, and the glaze amount of the second cosmetic soil is 360-380 g / m 2 , the whiteness value of the second cosmetic soil layer is 50-60 degrees, the thickness of the second cosmetic soil layer is 0.12-0.15 mm, the glossiness of the second cosmetic soil layer after sintering is 4-6 degrees, the whiteness value of the first cosmetic soil layer and the second cosmetic soil layer after superposition is 66-76 degrees, the thickness of the first cosmetic soil layer and the second cosmetic soil layer after superposition is 0.2-0.25 mm, and the glossiness of the first cosmetic soil layer and the second cosmetic soil layer after superposition is 4-6 degrees. In other words, the embodiment of the present application not only introduces industrial tailings sand into the first cosmetic soil, but also ensures that the whiteness value of the two layers of cosmetic soil is the same as that of conventional cosmetic soil, or even whiter.

[0062] In one embodiment of the present application, the first cosmetic soil is prepared according to the first cosmetic soil raw material formula, and the second cosmetic soil is prepared according to the second cosmetic soil raw material formula, including:

[0063] According to the first cosmetic soil raw material formula, each raw material is put into a ball mill, and water is added to grind for 4 to 6 hours, and after iron removal, sieving, and aging, the first cosmetic soil is obtained;

[0064] The first cosmetic soil has a fineness of 0.4% to 0.6% of the 325-mesh sieve residue, a specific gravity of 1.70 to 1.75, and an Engler viscosity of 33 to 36S.

[0065] The second cosmetic soil is prepared according to the second cosmetic soil raw material formula, including:

[0066] According to the second cosmetic soil raw material formula, each raw material is put into a ball mill, and water is added to grind for 5 to 6 hours, and after iron removal, sieving, and aging, the second cosmetic soil is obtained;

[0067] The second cosmetic soil has a fineness of 0.4% to 0.5% of the residue on a 325-mesh sieve, a specific gravity of 1.78 to 1.82, and an Engler viscosity of 28 to 32S.

[0068] Specifically, the raw materials are put into a ball mill, ground with water, and ground for 4 to 6 hours to obtain a cosmetic soil slurry. The first cosmetic soil does not contain zirconium silicate and has a high kaolin content. The amount of water added during ball milling is more than that of conventional cosmetic soil. The fineness of the first cosmetic soil is 0.4% to 0.6% of the 325-mesh sieve residue, the specific gravity is 1.70 to 1.75, and the Eng viscosity is 33 to 36S. When removing iron and sieving, the ground glaze slurry is filtered through a 100-mesh double-layer sieve. After removing iron through an iron removal tank, the glaze slurry is pumped to a slurry pool for aging to obtain the first cosmetic soil. In order to obtain finer fineness and thus higher whiteness, the second cosmetic soil is prepared by putting all raw materials into a ball mill, adding water and grinding for 5 to 6 hours, and after deironing, sieving and aging, the second cosmetic soil is obtained. The fineness of the second cosmetic soil is 0.4%-0.5% of the 325 mesh residue, the specific gravity is 1.78-1.82, and the Engler viscosity is 28-32S. Of course, the preparation parameters of the second cosmetic soil can also be controlled according to conventional production.

[0069] like Figure 1 As shown, the method for preparing the ceramic tile with double-layer cosmetic soil according to the embodiment of the present invention also includes:

[0070] Step S200: applying the first cosmetic soil on the pre-prepared ceramic body to obtain a first cosmetic soil layer.

[0071] Specifically, the ceramic green body in the present application is a green body produced by a conventional ceramic tile production process, that is, the ceramic tile green body is obtained according to a conventional ceramic tile process method and is set aside.

[0072] In an embodiment of the present application, the whiteness value of the first makeup soil layer is 40 to 50 degrees, the glossiness of the first makeup soil layer after sintering is 3.5 to 5 degrees, the whiteness value of the second makeup soil layer is 50 to 60 degrees, the glossiness of the second makeup soil layer after sintering is 4 to 6 degrees, and the whiteness value of the first makeup soil layer + the second makeup soil layer is 66 to 76 degrees.

[0073] Specifically, the first cosmetic soil raw material formula is used for ball milling and slurrying, and 295-310 g / m2 of the raw material is applied to the ceramic tile blank. 2 The first cosmetic soil is fired after being fired, and the whiteness value of the first cosmetic soil layer is measured to be 40-50 degrees. The thickness of the first cosmetic soil layer is measured by an electron microscope, and the thickness is 0.08-0.1 mm. The sintering degree of the first cosmetic soil layer is characterized by the glossiness instrument measurement value, and the glossiness is 3.5-5 degrees. No pinholes are caused after firing; ball milling is performed according to the second cosmetic soil raw material formula, and 360-380g / m 2The second cosmetic soil is fired, and the whiteness value of the second cosmetic soil layer is measured to be 50-60 degrees. The thickness of the second cosmetic soil layer is measured by an electron microscope, and the thickness is 0.12-0.15 mm. The sintering degree of the second cosmetic soil layer is characterized by the glossiness instrument measurement value, and the glossiness is 4-6 degrees. No pinholes are caused after firing; ball milling is performed according to the first and second cosmetic soil raw material formulas, and 295-310 g / m2 is applied on the ceramic tile blank. 2 After the first cosmetic soil, apply 360-380g / m 2 The second makeup soil is fired, and the whiteness value of the double-layer makeup soil is measured to be 66 to 76 degrees. The thickness of the second makeup soil layer is measured using an electron microscope, and the thickness is 0.2 to 0.25 mm. The sintering degree of the double-layer makeup soil layer is characterized by a glossiness instrument measurement value, and the glossiness is 4 to 6 degrees.

[0074] The embodiment of the present application can ensure that a cosmetic soil layer with better flatness and whiteness is obtained.

[0075] like Figure 1 As shown, the method for preparing the ceramic tile with double-layer cosmetic soil according to the embodiment of the present invention also includes:

[0076] Step S300: applying the second cosmetic soil on the ceramic body to which the first cosmetic soil layer has been applied, to obtain a second cosmetic soil layer.

[0077] The present invention adjusts the glazing process of the cosmetic soil, changes the original application of a thick cosmetic soil layer to the application of two thin cosmetic soil layers, the thickness of the first cosmetic soil layer after firing is 0.08-0.1mm, the thickness of the second cosmetic soil layer after firing is 0.12-0.15mm, the two cosmetic soil layers are applied to the surface of the ceramic tile body in sequence, the thickness of the double-layer cosmetic soil layer after firing is 0.2-0.25mm, and the overall thickness of the bottom glaze (0.2-0.25mm) is ensured to be greater than the previous thickness (0.18-0.22mm), so as to ensure that the glazing has better flatness and whiteness. Specifically, the temperature of the ceramic body is 80-90°C, the brick walking speed of the ceramic body between applying the first cosmetic soil and the second cosmetic soil is 50m / min, and the distance from the first cosmetic soil glazing position to the second cosmetic soil glazing position is 12-18m, ensuring that when the second cosmetic soil is applied, there is no obvious trace of moisture on the surface of the brick when viewed from the side, and it can be ensured that at this time the moisture of the first cosmetic soil has been basically evaporated and absorbed by the body and the body maintains a certain degree of wetness, avoiding the situation where the distance is too short and the second cosmetic soil is directly applied before the moisture of the first cosmetic soil on the brick is completely evaporated and absorbed, causing orange peel defects in the product, and avoiding the situation where the distance is too long and the first cosmetic soil is completely dry, the body surface is too dry, the wetness is insufficient, and pinhole defects are prone to occur.

[0078] The embodiment of the present application innovates the glazing process of cosmetic soil, changing from pouring a thick glaze once to pouring a thinner glaze twice. Due to the high water content of the glaze slurry, when the cosmetic soil layer is applied with a thick glaze, its water absorption rate is slow, which is easy to produce the "orange peel" phenomenon of the glaze surface, affecting the flatness of the product after pouring the glaze. When it is changed to pouring two thinner glazes, the first thinner cosmetic soil can quickly absorb water and form a water molecule channel after application, and the second thinner cosmetic soil can also quickly absorb water after being applied on its surface, ensuring the flatness of the glazing. Therefore, the glazing flatness of the present application after two glazings is better. Therefore, the embodiment of the present application improves the flatness of the product glaze surface, the polishing effect, and the polishing efficiency by increasing the overall glaze layer thickness of the product.

[0079] The parameter comparison between the first cosmetic soil layer and the second cosmetic soil layer obtained in the embodiment of the present application is shown in Table 1:

[0080] Table 1

[0081]

[0082] The linear expansion coefficient of the first cosmetic soil layer in the embodiment of the present application is close to that of conventional cosmetic soil, and has little effect on the brick shape. In addition, due to the increase in the total glazing thickness of the cosmetic soil, the flatness of the glaze surface is guaranteed, and the amount of transparent glaze with a smaller linear expansion coefficient can be appropriately reduced, which has a positive effect on stabilizing the flatness deformation of the product and reducing production costs.

[0083] In one embodiment, the total glazing dry material amount of the conventional cosmetic soil + conventional transparent glaze solution is 636.4 g / m 2 The glaze cost is 1.5917 yuan / m 2 The total glazing dry material amount of the first layer of cosmetic soil + the second layer of cosmetic soil + the transparent glaze in the embodiment of the present application is 703.9 g / m 2 The glaze cost is 1.3457 yuan / m 2 Compared with the original product, the total amount of glazing dry materials of the present invention increased by 10.6%, and the cost was reduced by 15.45%. As shown in Table 2:

[0084] Table 2

[0085]

[0086] The glaze surface smoothness is expressed by the measurement value of the roughness instrument. The roughness instrument is used to measure the surface roughness of the product. The larger the measurement value, the rougher the surface and the worse the smoothness. As shown in Table 3:

[0087] Table 3

[0088] Comparison parameters Roughness(μm) Original product single cosmetic clay fired glaze 3.647～4.165 The double-layer cosmetic soil of the present invention is fired into glaze 3.267～3.589 The original product is glazed with transparent glaze and then fired into glazed surface 1.528～1.865 The present invention applies transparent glaze and then fires the glaze surface 1.348～1.415

[0089] The brick type comparison results of the product of the present invention and the original product are shown in Table 4:

[0090] Table 4

[0091]

[0092] like Figure 1 As shown, the method for preparing the ceramic tile with double-layer cosmetic soil according to the embodiment of the present invention also includes:

[0093] Step S400: Processing the ceramic body with the first makeup soil layer and the second makeup soil layer applied thereto to obtain a ceramic tile.

[0094] In an embodiment of the present application, the step S400 specifically includes: performing pattern decoration treatment on a ceramic body provided with a first cosmetic soil layer and a second cosmetic soil layer to obtain a decorated body; after applying a transparent glaze on the surface of the decorated body, firing it in a kiln at a high temperature to obtain a ceramic tile.

[0095] Specifically, the product is put into a kiln for high-temperature firing, and the surface of the fired product is polished or not polished to obtain a ceramic tile. The specific process diagram is as follows Figure 2 shown.

[0096] The embodiment of the present application divides the conventional one-layer cosmetic soil layer used in the production of ceramic tile products in the industry into two layers, which are applied in small amounts multiple times, reducing the amount of glaze applied each time, making it easier for the green body to absorb. After the double layers of cosmetic soil are superimposed, the glaze layer is smoother, and the production quality of the product is improved. It avoids the use of a large amount of cosmetic soil applied at one time, resulting in a thick glaze layer and slow water absorption of the glaze slurry, which leads to the orange peel phenomenon. The first layer of cosmetic soil is a high-ball clay, high-tailings, zirconium-free formula system cosmetic soil, which can consume a large amount of industrial tailings sand and reduce the use of expensive zirconium silicate raw materials. Multiple measures are taken to greatly reduce production costs.

[0097] Specific embodiments are listed below for illustration.

[0098] Embodiment 1

[0099] Step A1, by weight, 4 to 6 parts of potassium feldspar, 6.3 to 6.8 parts of calcined talc, 23 to 25 parts of kaolin, and 64 to 67 parts of industrial tailings sand are put into a ball mill, and water is added to grind for 4 to 6 hours, and after iron removal, sieving, and aging, a first cosmetic soil is obtained; the fineness of the first cosmetic soil is 0.4% to 0.6% of the 325 mesh sieve residue, the specific gravity is 1.70 to 1.75, and the Engler viscosity is 33 to 36S. In addition, 8-9 parts of potassium feldspar, 12-15 parts of zirconium silicate, 2-3 parts of calcined talc, 12-15 parts of quartz, 6-9 parts of wollastonite, 8-9 parts of kaolin, 2-3 parts of aluminum oxide, and 41-43 parts of nepheline are put into a ball mill by weight, and ground with water for 5-6 hours, and after iron removal, sieving, and aging, a second cosmetic soil is obtained; the fineness of the second cosmetic soil is 0.4%-0.5% of the residue on a 325-mesh sieve, the specific gravity is 1.78-1.82, and the Engler viscosity is 28-32S.

[0100] Step A2: applying the first cosmetic soil on the pre-prepared ceramic body to obtain a first cosmetic soil layer.

[0101] Step A3, applying the second cosmetic soil on the ceramic body to which the first cosmetic soil layer has been applied, to obtain a second cosmetic soil layer;

[0102] Step A4, performing pattern decoration treatment on the ceramic body applied with the first cosmetic soil layer and the second cosmetic soil layer to obtain a decorated body;

[0103] Step A5: After applying transparent glaze on the surface of the decorated body, the body is put into a kiln for high-temperature firing to obtain a ceramic tile.

[0104] Embodiment 2

[0105] Step B1, by weight, 5 parts of potassium feldspar, 6 parts of calcined talc, 25 parts of kaolin, and 60 parts of industrial tailings sand are put into a ball mill, and water is added to grind for 4 hours, and after iron removal, sieving, and aging, a first cosmetic soil is obtained; the fineness of the first cosmetic soil is 0.4% to 0.6% of the 325 mesh residue, the specific gravity is 1.70 to 1.75, and the Engler viscosity is 34 to 35S. And, by weight, 8 parts of potassium feldspar, 12 parts of zirconium silicate, 3 parts of calcined talc, 13 parts of quartz, 9 parts of wollastonite, 9 parts of kaolin, 3 parts of aluminum oxide, and 43 parts of nepheline are put into a ball mill, and water is added to grind for 6 hours, and after iron removal, sieving, and aging, a second cosmetic soil is obtained; the fineness of the second cosmetic soil is 0.4%-0.5% of the residue on a 325-mesh sieve, the specific gravity is 1.78-1.82, and the Engler viscosity is 28-30S, so as to obtain a second cosmetic soil.

[0106] Step B2: applying the first cosmetic soil on the pre-prepared ceramic body to obtain a first cosmetic soil layer.

[0107] Step B3, applying the second cosmetic soil on the ceramic body to which the first cosmetic soil layer has been applied, to obtain a second cosmetic soil layer;

[0108] Step B4, performing pattern decoration treatment on the ceramic body applied with the first cosmetic soil layer and the second cosmetic soil layer to obtain a decorated body;

[0109] Step B5: After applying transparent glaze on the surface of the decorated body, the body is put into a kiln for high-temperature firing to obtain a ceramic tile.

[0110] Embodiment 3

[0111] Step C1, by weight, 6 parts of potassium feldspar, 7 parts of calcined talc, 20 parts of kaolin, and 66 parts of industrial tailings sand are put into a ball mill, and water is added to grind for 5 hours, and after iron removal, sieving, and aging, a first cosmetic soil is obtained; the fineness of the first cosmetic soil is 0.4% to 0.5% of the 325 mesh residue, the specific gravity is 1.72 to 1.75, and the Engler viscosity is 35 to 36S. And by weight, 10 parts of potassium feldspar, 10 parts of zirconium silicate, 2 parts of calcined talc, 12 parts of quartz, 8 parts of wollastonite, 10 parts of kaolin, 1 part of aluminum oxide, and 40 parts of nepheline are put into a ball mill, and water is added to grind for 5 hours, and after iron removal, sieving, and aging, a second cosmetic soil is obtained; the fineness of the second cosmetic soil is 0.4%-0.5% of the residue on a 325-mesh sieve, the specific gravity is 1.78-1.80, and the Engler viscosity is 29-31S, and the second cosmetic soil is obtained. .

[0112] Step C2: applying the first cosmetic soil on the pre-prepared ceramic body to obtain a first cosmetic soil layer.

[0113] Step C3, applying the second cosmetic soil on the ceramic body to which the first cosmetic soil layer has been applied, to obtain a second cosmetic soil layer;

[0114] Step C4, performing pattern decoration treatment on the ceramic body applied with the first cosmetic soil layer and the second cosmetic soil layer to obtain a decorated body;

[0115] Step C5: After applying transparent glaze on the surface of the decorated body, the body is put into a kiln for high-temperature firing to obtain a ceramic tile.

[0116] The embodiments of the present application achieve the following effects:

[0117] First, the embodiment of the present application uses cheap industrial tailings sand raw materials, which have a high sintering temperature. By adjusting the sintering degree of the formula through fluxes such as talc, the amount of industrial tailings sand can reach 70%, reducing the formula cost, while turning waste into treasure and reducing environmental pollution caused by tailings landfill, with good economy and environmental protection.

[0118] Second, the embodiment of the present application innovates the glazing process of cosmetic soil, changing from pouring a thick glaze once to pouring a thin glaze twice. Since the water content of the glaze slurry is relatively high, when the cosmetic soil layer is applied as a thick glaze, its water absorption rate is relatively slow, which is easy to produce the "orange peel" phenomenon of the glaze surface, affecting the flatness of the product after pouring the glaze. When it is changed to pouring two thinner glazes, the first thinner cosmetic soil can quickly absorb water and form a water molecule channel after application, and the second thinner cosmetic soil can also quickly absorb water after being applied on its surface, ensuring the flatness of the glazing, so the glazing flatness is better after changing to two glazings.

[0119] Third, the overall glaze amount of the cosmetic soil in the embodiment of the present application is increased, and the flatness is improved, which is more conducive to the deformation control of the glazed tiles, and also provides a basis for reducing the glaze amount for the transparent glaze with a smaller expansion coefficient.

[0120] Fourth, in addition to the economic benefits, the embodiment of the present application also effectively improves the flatness of the glaze surface, which has a positive effect on improving product quality and improving the efficiency of the polishing process.

[0121] The present application also provides a ceramic tile, wherein the ceramic tile is prepared by the preparation method of the ceramic tile with a double-layer cosmetic soil as described above.

[0122] The present invention provides a method for preparing a ceramic tile with a double-layer cosmetic soil and a ceramic tile, wherein the method for preparing the ceramic tile with a double-layer cosmetic soil comprises: preparing a first cosmetic soil according to a first cosmetic soil raw material formula, and preparing a second cosmetic soil according to a second cosmetic soil raw material formula; applying the first cosmetic soil on a pre-prepared ceramic body to obtain a first cosmetic soil layer; applying the second cosmetic soil on the ceramic body to which the first cosmetic soil layer has been applied to obtain a second cosmetic soil layer; and treating the ceramic body to which the first cosmetic soil layer and the second cosmetic soil layer have been applied to obtain a ceramic tile. The present invention prepares two cosmetic soil slurries, adjusts the cosmetic soil one-time glazing process to a two-time thin glazing layer process, solves the glazing "orange peel" problem, improves the glazing flatness, reduces the zirconium silicate content in the overall glaze, and reduces the production cost.

[0123] It should be understood that the application of the present invention is not limited to the above examples. For ordinary technicians in this field, improvements or changes can be made based on the above description. All these improvements and changes should fall within the scope of protection of the claims attached to the present invention.

Claims

1. A method for preparing a ceramic tile with a double-layer cosmetic soil, characterized in that: include: A first cosmetic soil is prepared according to the first cosmetic soil raw material formula, and a second cosmetic soil is prepared according to the second cosmetic soil raw material formula; Applying the first cosmetic soil on the pre-prepared ceramic body to obtain a first cosmetic soil layer; Applying the second cosmetic soil on the ceramic body to which the first cosmetic soil layer has been applied, to obtain a second cosmetic soil layer; The ceramic body with the first makeup soil layer and the second makeup soil layer applied thereto is processed to obtain a ceramic tile.

2. The method for preparing a ceramic tile with a double-layer cosmetic soil according to claim 1, characterized in that: The raw material formula of the first cosmetic soil is different from the raw material formula of the second cosmetic soil. The first cosmetic soil is a cosmetic soil with a high ball clay, high tailings and no zirconium formula system, and the second cosmetic soil is a cosmetic soil with a high pyroxene formula system.

3. The method for preparing a ceramic tile with a double-layer cosmetic soil according to claim 1, characterized in that: The first cosmetic soil raw material formula has a kaolin content of ≥20% by weight, an industrial tailings sand content of ≥60% by weight, and a zirconium-containing material content of 0 by weight. The second cosmetic soil raw material formula has a nepheline content of ≥40% by weight.

4. The method for preparing a ceramic tile with a double-layer cosmetic soil according to claim 1, characterized in that: The raw materials in the first cosmetic soil raw material formula include, by weight: 4-6 parts of potassium feldspar, 5-7 parts of calcined talc, 20-27 parts of kaolin, 60-70 parts of industrial tailings sand; The raw materials in the second cosmetic soil raw material formula include, by weight: 8-10 parts of potassium feldspar, 10-18 parts of zirconium silicate, 1-3 parts of calcined talc, 10-15 parts of quartz, 5-10 parts of wollastonite, 8-10 parts of kaolin, 0-3 parts of aluminum oxide, and 40-45 parts of nepheline.

5. The method for preparing a ceramic tile with a double-layer cosmetic soil according to claim 1, characterized in that: The chemical components of the first cosmetic soil raw material formula, calculated by mass percentage, include: Loss on ignition 2%~4%, SiO2 68%~72%, Al2O3 16%~18%, Fe2O3 0~0.3%, CaO0~1%, MgO 2%~3%, K2O 2%~3%, Na2O 3%~4%; The chemical components of the second cosmetic soil raw material formula, calculated by mass percentage, include: Loss on ignition 3%~4%, SiO2 52%~60%, Al2O3 15%~20%, Fe2O3 0~0.25%, CaO 3%~5%, MgO 1%~1.5%, K2O 2%~3%, Na2O 4%~5%, ZrO2 7%~10%.

6. The method for preparing a ceramic tile with a double-layer cosmetic soil according to claim 1, characterized in that: The whiteness value of the single raw material in the first cosmetic soil raw material formula after sintering is 68-70 degrees, and the glaze amount of the first cosmetic soil is 295-310g / m 2 The whiteness value of the first cosmetic soil layer is 40-50 degrees, the thickness of the first cosmetic soil layer is 0.08-0.1 mm, and the glossiness of the first cosmetic soil layer after sintering is 3.5-5 degrees; the glaze amount of the second cosmetic soil is 360-380 g / m 2 The whiteness value of the second cosmetic soil layer is 50 to 60 degrees, the thickness of the second cosmetic soil layer is 0.12 to 0.15 mm, the glossiness of the second cosmetic soil layer after sintering is 4 to 6 degrees, the whiteness value of the first cosmetic soil layer and the second cosmetic soil layer after superposition is 66 to 76 degrees, the thickness of the first cosmetic soil layer and the second cosmetic soil layer after superposition is 0.2 to 0.25 mm, and the glossiness of the first cosmetic soil layer and the second cosmetic soil layer after superposition is 4 to 6 degrees.

7. The method for preparing a ceramic tile with a double-layer cosmetic soil according to claim 1, characterized in that: The first cosmetic soil is prepared according to the first cosmetic soil raw material formula, and the second cosmetic soil is prepared according to the second cosmetic soil raw material formula, including: According to the first cosmetic soil raw material formula, each raw material is put into a ball mill, and water is added to grind for 4 to 6 hours, and after iron removal, sieving, and aging, the first cosmetic soil is obtained; The first cosmetic soil has a fineness of 0.4% to 0.6% of the residue on a 325-mesh sieve, a specific gravity of 1.70 to 1.75, and an Engler viscosity of 33 to 36S; According to the second cosmetic soil raw material formula, each raw material is put into a ball mill, and water is added to grind for 5 to 6 hours, and after iron removal, sieving, and aging, the second cosmetic soil is obtained; The second cosmetic soil has a fineness of 0.4% to 0.5% of the residue on a 325-mesh sieve, a specific gravity of 1.78 to 1.82, and an Engler viscosity of 28 to 32S.

8. The method for preparing a ceramic tile with a double-layer cosmetic soil according to claim 1, characterized in that: The temperature of the ceramic body is 80-90° C., the brick-moving speed of the ceramic body between applying the first cosmetic soil and the second cosmetic soil is 50 m / min, and the distance from the glazing position of the first cosmetic soil to the glazing position of the second cosmetic soil is 12-18 m.

9. The method for preparing a ceramic tile with a double-layer cosmetic soil according to claim 1, characterized in that: The ceramic body with the first cosmetic soil layer and the second cosmetic soil layer applied thereto is processed to obtain a ceramic tile, comprising: Performing pattern decoration on the ceramic body provided with the first cosmetic soil layer and the second cosmetic soil layer to obtain a decorated body; After transparent glaze is applied on the surface of the decorated body, it is put into a kiln for high-temperature firing to obtain a ceramic tile.

10. A ceramic tile, characterized in that: The ceramic tile is prepared by the method for preparing a ceramic tile with a double-layer cosmetic soil as described in any one of claims 1 to 9.

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