A kind of ceramic permeable brick with imitation stone texture and its manufacturing method

Abstract

The present invention discloses a ceramic permeable brick imitating stone texture and a manufacturing method thereof. A ceramic permeable brick imitating stone texture comprises, from bottom to top, a base body bottom layer, a base body surface layer, a bottom glaze decoration layer, a pattern decoration layer, a surface glaze decoration layer and a functional glaze decoration layer. When the ratio of the nominal length to the nominal thickness of the ceramic permeable brick is less than or equal to 4 and it is a permeable road brick, the splitting tensile strength ≥ 3.0 MPa, and the water permeability coefficient is greater than or equal to 1.0×10 ‑2 cm / s; when the ratio of the nominal length to the nominal thickness of the ceramic permeable brick is greater than 4 and it is a permeable road slab, the flexural strength ≥ 3.0 MPa, and the water permeability coefficient is greater than or equal to 1.0×10 ‑2 cm / s. The permeable ceramic brick product proposed by the present invention has clear texture, rich pattern effects, and the product color can be selected arbitrarily, and the colors and textures of existing stones can be reproduced.

Description

Technical Field:

[0001] The present invention relates to the technical field of building materials, and particularly relates to a ceramic permeable brick with a stone-like texture and a manufacturing method thereof. Background Art:

[0002] Ceramic permeable bricks are a type of ceramic brick that can improve the urban heat island effect, reduce the urban drainage pressure, and can be recycled environmentally. In response to the call of the "Sponge City", they have entered the market selection vision. Currently, most of the ceramic permeable brick products on the market are unglazed and double-layer fabric products. First, the fabric layer uses waste ceramic particles and adds colorants to achieve the colors required by customers. Second, inkjet printing is performed on the basis of the fabric layer. The colors shown by these two decoration methods are relatively single.

[0003] Currently, there are studies on ceramic permeable bricks in the industry. Patents such as CN117229082A, CN116675554A, and CN113003989A disclose traditional processes that use ceramic waste as the main material, assisted by other solid wastes, and are stirred with binders and colorants, followed by firing and other processes. The characteristics of these processes are that they achieve color development by adding inorganic colorants, and the entire brick can only present one color, with relatively single colors.

[0004] The key points of the marble-like imitation disclosed in CN109534786A are: on the basis of traditional permeable bricks, the processes of protective glaze and inkjet printing are added. 1) This process adjusts the gray scale to 60%-70%, and the presented texture is blurred and cannot perfectly present the marble texture; 2) This process has high requirements for the purity of the product blank. It is urgent to solve the above problems and develop new permeable ceramic bricks. Summary of the Invention:

[0005] The present invention solves the problems existing in the prior art, and provides a ceramic permeable brick with a stone-like texture and a manufacturing method thereof. The ceramic permeable brick obtained by the manufacturing method proposed by the present invention has a stone-like effect, and the product has stone textures such as sesame white, sesame gray, sesame black, night snow, and wave-washed sand. At the same time, the process is simple and easy to implement.

[0006] The purpose of the present invention is to provide a ceramic permeable brick with a stone-like texture, which sequentially includes a blank bottom layer, a blank fabric layer, a bottom glaze decoration layer, a pattern decoration layer, a surface glaze decoration layer, and a functional glaze decoration layer from bottom to top. According to the standard of permeable pavement bricks and permeable road panels GB / T25993-2023, when the ratio of the nominal length to the nominal thickness is less than or equal to 4 for permeable pavement bricks, the splitting tensile strength ≥ 3.0 MPa, and the permeability coefficient is greater than or equal to 1.0×10 -2 cm / s; when the ratio of the nominal length to the nominal thickness is greater than 4 for permeable road panels, the flexural strength ≥ 3.0 MPa, and the permeability coefficient is greater than or equal to 1.0×10 -2cm / s.

[0007] For this ceramic permeable brick, the thickness of the base material layer of the green body is 22 - 75 mm, the thickness of the surface material layer of the green body is 8 - 10 mm, the thickness of the base glaze decoration layer is 0.1 - 0.2 mm, the thickness of the surface glaze decoration layer is 0.05 - 0.1 mm, and the thickness of the functional glaze decoration layer is 0.5 - 1 mm.

[0008] Preferably, the surface glaze decoration layer is prepared by the following steps: spraying glaze on the pattern decoration layer to obtain the surface glaze decoration layer, and the process parameters of spraying glaze are: the specific gravity of the glaze slurry is 1.15 - 1.25 g / cm 3 , the flow rate of the glaze slurry is 11 - 13 s / 100 mL, the sieve residue of the glaze slurry through a 250 - mesh sieve is 0.5% - 0.7%, and the glaze application amount is 145 - 220 g / m 2 .

[0009] Preferably, the formula of the surface glaze in the surface glaze decoration layer is: by dry weight parts, including 28 - 32 parts of potassium feldspar, 0.1 - 0.3 parts of methyl cellulose, 0.1 - 0.3 parts of sodium tripolyphosphate, 15 - 20 parts of barium carbonate, 8 - 10 parts of dolomite, 13 - 18 parts of albite, 6 - 10 parts of calcined talc, 3 - 5 parts of zinc oxide, 5 - 10 parts of kaolin and 5 - 10 parts of low - temperature frit, and additionally 45 - 55 parts of water.

[0010] More preferably, the formula of the surface glaze in the surface glaze decoration layer is: by dry weight parts, including 30 parts of potassium feldspar, 0.2 parts of methyl cellulose, 0.2 parts of sodium tripolyphosphate, 18 parts of barium carbonate, 9 parts of dolomite, 15 parts of albite, 8 parts of calcined talc, 4 parts of zinc oxide, 8 parts of kaolin and 8 parts of low - temperature frit, and additionally 50 parts of water.

[0011] Preferably, the formula of the functional glaze in the functional glaze decoration layer is: by parts by mass, including 62 - 67 parts of dry granule suspending agent, 0.1 - 0.3 parts of methyl cellulose, 13 - 20 parts of water and 15 - 18 parts of environmentally friendly dry granules.

[0012] More preferably, the formula of the functional glaze in the functional glaze decoration layer is: by parts by mass, including 66 parts of dry granule suspending agent, 0.1 part of methyl cellulose, 16 parts of water and 18 parts of environmentally friendly dry granules.

[0013] The present invention also provides a manufacturing method of the ceramic permeable brick with simulated stone texture, including the following steps:

[0014] (1) Crushing the ceramic waste bricks to obtain crushed materials, removing iron according to the particle size of the crushed materials and then classifying them, which are respectively: 6 - 8 mesh, 8 - 14 mesh, 14 - 30 mesh and below 30 mesh;

[0015] (2) The crushed ceramic waste brick particles after classification in step (1) are formulated into the top layer material and the bottom layer material according to whiteness and particle size respectively. The bottom layer material is mixed with a binder, and the moisture content of the obtained mixture is controlled at 3.8% - 4.2%. After uniform mixing, a bottom layer blank is obtained, and the bottom layer blank is pressed into shape to obtain a bottom layer of the blank body;

[0016] (3) The top layer material obtained in step (2) is mixed with a binder, and the moisture content of the obtained mixture is controlled at 3.8% - 4.2%. After uniform mixing, a top layer blank is obtained, and the top layer blank is pressed into shape to obtain a top layer of the blank body;

[0017] (4) A bottom glaze is applied to the top layer of the blank body to obtain a bottom glaze decorative layer. The process parameters for applying the bottom glaze are: the specific gravity of the glaze slurry is 1.49 - 1.51 g / cm 3 , the flow rate of the glaze slurry is 13 - 15 s / 100 mL, the sieve residue of the glaze slurry through a 250 - mesh sieve is 0.5% - 0.7%, and the glaze application amount is 440 - 550 g / m 2 ;

[0018] (5) Pattern decoration printing is carried out several times on the bottom glaze decorative layer to obtain a pattern decorative layer;

[0019] (6) Glaze is sprayed on the pattern decorative layer to obtain a top glaze decorative layer. The process parameters for spraying the glaze are: the specific gravity of the glaze slurry is 1.15 - 1.25 g / cm 3 , the flow rate of the glaze slurry is 11 - 13 s / 100 mL, the sieve residue of the glaze slurry through a 250 - mesh sieve is 0.5% - 0.7%, and the glaze application amount is 145 - 220 g / m 2 ;

[0020] (7) A functional glaze is applied to the top glaze decorative layer to obtain a functional glaze decorative layer. The process parameters are: the specific gravity of the glaze slurry is 1.4 - 1.5 g / cm 3 , the flow rate of the glaze slurry is 55 - 60 s / 100 mL, and the glaze application amount is 150 - 220 g / m 2 ;

[0021] (8) The semi - finished product decorated through the above steps is fired. The firing temperature is 1180°C - 1200°C, and the firing time is 360 - 480 minutes to obtain the ceramic permeable brick with simulated stone texture.

[0022] In the present invention, the ceramic waste bricks refer to ceramic waste products such as rock slabs, polished bricks, antique bricks, stone - like bricks, and daily - use ceramics generated by each ceramic enterprise, which were mainly used as building fillers or waste materials before. The method for recycling and homogenizing the ceramic waste bricks is: distinguishing the ceramic waste bricks according to whiteness and water absorption rate, placing the waste bricks with different whiteness and water absorption rates separately, and carrying out multi - round flipping homogenization on them.

[0023] Preferably, the base stock in step (3), by mass parts, comprises the following components: 15 - 25 parts of variegated ceramic waste bricks with a size of 6 - 8 mesh, 45 - 55 parts of variegated ceramic waste bricks with a size of 8 - 14 mesh, 15 - 25 parts of variegated ceramic waste bricks with a size of 14 - 30 mesh, 8 - 12 parts of variegated ceramic waste bricks with a size below 30 mesh, 6 - 10 parts of binder, and 3 - 5 parts of water.

[0024] More preferably, the base stock in step (3), by mass parts, comprises the following components: 20 parts of variegated ceramic waste bricks with a size of 6 - 8 mesh, 50 parts of variegated ceramic waste bricks with a size of 8 - 14 mesh, 20 parts of variegated ceramic waste bricks with a size of 14 - 30 mesh, 10 parts of variegated ceramic waste bricks with a size below 30 mesh, 8 parts of binder, and 4 parts of water.

[0025] Preferably, the facing stock in step (2), by mass parts, comprises the following components: 8 - 12 parts of white ceramic waste bricks with a size of 8 - 14 mesh, 30 - 40 parts of white ceramic waste bricks with a size of 14 - 30 mesh, 18 - 22 parts of variegated ceramic waste bricks with a size of 8 - 14 mesh, 20 - 30 parts of variegated ceramic waste bricks with a size of 14 - 30 mesh, 8 - 12 parts of variegated ceramic waste bricks with a size below 30 mesh, 6 - 10 parts of binder, and 3 - 5 parts of water.

[0026] More preferably, the facing stock in step (2), by mass parts, comprises the following components: 10 parts of white ceramic waste bricks with a size of 8 - 14 mesh, 35 parts of white ceramic waste bricks with a size of 14 - 30 mesh, 20 parts of variegated ceramic waste bricks with a size of 8 - 14 mesh, 25 parts of variegated ceramic waste bricks with a size of 14 - 30 mesh, 10 parts of variegated ceramic waste bricks with a size below 30 mesh, 8 parts of binder, and 4 parts of water.

[0027] The mixing step of the facing stock or the base stock is specifically as follows: The ceramic waste brick particles configured in proportion are successively fed into a mixer and stirred for 2 minutes, then water is added and stirred for 3 minutes to make the surfaces of the ceramic waste brick particles uniformly moist, and then the binder is added and stirred for 4 minutes.

[0028] Preferably, the binder in step (2) or (3), by mass parts, comprises the following components: 80 - 88 parts of bentonite, 0.8 - 1.2 parts of methyl cellulose, 8 - 12 parts of kaolin, and 4 - 6 parts of albite.

[0029] More preferably, the binder in step (2) or (3), by mass parts, comprises the following components: 84 parts of bentonite, 1 part of methyl cellulose, 10 parts of kaolin, and 5 parts of albite.

[0030] Preferably, the base glaze formula in the base glaze decorative layer described in step (4) is as follows: in terms of dry weight parts by mass, it includes 22-28 parts of potassium feldspar, 6-10 parts of zirconium silicate, 0.1-0.3 parts of methyl cellulose, 0.2-0.4 parts of sodium tripolyphosphate, 6-10 parts of barium carbonate, 6-10 parts of kaolin, 12-18 parts of albite, 8-12 parts of aluminum chloride, 3-5 parts of zinc oxide, 5-10 parts of quartz, 1-3 parts of calcined talc, and 4-6 parts of nepheline syenite, and an additional 45-55 parts of water.

[0031] Further preferably, the base glaze formula in the base glaze decorative layer described in step (4) is as follows: in terms of dry weight parts by mass, it includes 25 parts of potassium feldspar, 8 parts of zirconium silicate, 0.2 parts of methyl cellulose, 0.3 parts of sodium tripolyphosphate, 8 parts of barium carbonate, 8 parts of kaolin, 15 parts of albite, 10 parts of aluminum chloride, 4 parts of zinc oxide, 7 parts of quartz, 2 parts of calcined talc, and 5 parts of nepheline syenite, and an additional 50 parts of water.

[0032] Preferably, the surface glaze formula in the surface glaze decorative layer described in step (6) is as follows: in terms of dry weight parts by mass, it includes 28-32 parts of potassium feldspar, 0.1-0.3 parts of methyl cellulose, 0.1-0.3 parts of sodium tripolyphosphate, 15-20 parts of barium carbonate, 8-10 parts of dolomite, 13-18 parts of albite, 6-10 parts of calcined talc, 3-5 parts of zinc oxide, 5-10 parts of kaolin, and 5-10 parts of low-temperature frit, and an additional 45-55 parts of water.

[0033] Further preferably, the surface glaze formula in the surface glaze decorative layer described in step (6) is as follows: in terms of dry weight parts by mass, it includes 30 parts of potassium feldspar, 0.2 parts of methyl cellulose, 0.2 parts of sodium tripolyphosphate, 18 parts of barium carbonate, 9 parts of dolomite, 15 parts of albite, 8 parts of calcined talc, 4 parts of zinc oxide, 8 parts of kaolin, and 8 parts of low-temperature frit, and an additional 50 parts of water.

[0034] Preferably, the functional glaze formula in the functional glaze decorative layer described in step (7) is as follows: in terms of parts by mass, it includes 66-68 parts of dry granule suspending agent, 0.1-0.3 parts of methyl cellulose, 10-20 parts of water, and 18-22 parts of environmentally friendly dry granules.

[0035] Further preferably, the functional glaze formula in the functional glaze decorative layer described in step (7) is as follows: in terms of parts by mass, it includes 66 parts of dry granule suspending agent, 0.1 part of methyl cellulose, 16 parts of water, and 18 parts of environmentally friendly dry granules.

[0036] Compared with the prior art, the present invention has the following advantages: Compared with the existing ceramic permeable bricks in the market, on the premise of having the permeable function, the present invention also has the following advantages: 1. The product texture is clear and the pattern effect is rich; 2. The product color can be selected arbitrarily, and the colors and textures of existing stones can be reproduced, which cannot be achieved by the existing permeable bricks in the market; 3. The surface glaze decoration is added, and the anti-fouling performance is significantly improved compared with the existing permeable bricks in the market (as shown below Figure 3 ); 4. The functional glaze is added, and the anti-slip performance can reach 60 BPN. BRIEF DESCRIPTION OF THE DRAWINGS:

[0037] Figure 1 is a schematic structural diagram of the ceramic permeable brick proposed by the present invention;

[0038] Figure 2 is a surface view of the bottom glaze decoration layer obtained after the bottom glaze decoration in Example 1;

[0039] Figure 3 is a comparison diagram of the anti-fouling ability between the ceramic permeable brick obtained in Example 1 and the existing ceramic permeable bricks in the market. Among them, 1 and 2 are the comparisons before and after anti-fouling of Example 1; 3 and 4 are the comparisons before and after anti-fouling of the existing ceramic permeable bricks in the market;

[0040] BRIEF DESCRIPTION OF THE DRAWINGS: 1. Body bottom material layer; 2. Body surface material layer; 3. Bottom glaze decoration layer; 4. Pattern decoration layer; 5. Surface glaze decoration layer; 6. Functional glaze decoration layer. DETAILED DESCRIPTION OF THE EMBODIMENTS:

[0041] The following embodiments are further descriptions of the present invention, rather than limitations on the present invention.

[0042] Unless otherwise defined, all professional terms used hereinafter have the same meaning as commonly understood by those skilled in the art. The professional terms used herein are only for the purpose of describing specific embodiments, and are not intended to limit the protection scope of the present invention. Unless otherwise specified, the experimental materials and reagents in this article are all conventional commercially available products in this technical field. The low-temperature frit is purchased from Tangye Frit Factory, and the product number is C0018; the dry granule suspending agent is purchased from Keminghai, and the product number is C0067; the methyl cellulose is purchased from Cuixin, and the product number is CVH9; the environmentally friendly dry granules (ceramic dry granules) are purchased from Foshan Zhongrunlin Building Materials Technology Co., Ltd.

[0043] As Figure 1 shown, a ceramic permeable brick with a stone-like texture includes, from bottom to top, a body bottom material layer 1, a body surface material layer 2, a bottom glaze decoration layer 3, a pattern decoration layer 4, a surface glaze decoration layer 5, and a functional glaze decoration layer 6.

[0044] The manufacturing method of the above-mentioned ceramic permeable brick with a stone-like texture has the following main process technical routes:

[0045] Recycling of ceramic waste bricks → Crushing → Billet batching → Mixing → Spreading → Compression molding → Drying → Priming glaze decoration → Drying on the glaze line → Digital pattern decoration → Topcoat glaze decoration → Functional glaze decoration → Firing.

[0046] This manufacturing method specifically includes the following steps:

[0047] (1) Recycling and homogenization of ceramic waste bricks: Ceramic waste bricks refer to ceramic waste products such as slab stones, polished bricks, antique bricks, stone imitation bricks, and daily-use ceramics generated by various ceramic enterprises. Previously, they were mainly used as building fillers or waste materials. The method for their recycling and homogenization is as follows: Classify the waste bricks according to whiteness and water absorption, place waste bricks with different whiteness and water absorption separately, and conduct multiple rounds of turning and homogenization on them;

[0048] (2) Crushing the ceramic waste bricks to obtain crushed materials, separately crushing and processing them through a jaw crusher and a hammer crusher, and classifying them by high magnetic iron removal according to the particle size of the crushed materials, mainly divided into: 6 - 8 mesh, 8 - 14 mesh, 14 - 30 mesh, and above 30 mesh, in order to facilitate the formulation adjustment of product properties such as size, flexural strength, and water permeability;

[0049] (3) Formulating the top layer and bottom layer materials respectively from the classified ceramic waste brick crushed materials in step (2) according to whiteness and particle size, mixing the bottom layer material with a binder, controlling the moisture content of the mixed ingredient to 3.8% - 4.2%, being able to form a ball when held in the hand with stickiness, obtaining the bottom layer billet after uniform mixing, pressing and molding the bottom layer billet, and drying it to obtain the bottom layer 1 of the billet;

[0050] (4) Mixing the top layer material obtained in step (3) with a binder, controlling the moisture content of the mixed ingredient to 3.8% - 4.2%, obtaining the top layer billet after uniform mixing, pressing and molding the top layer billet, and drying it to obtain the top layer 2 of the billet;

[0051] (5) Spraying the primer glaze on the top layer of the billet to obtain the primer glaze decoration layer 3. The process parameters for spraying the primer glaze are as follows: The specific gravity of the glaze slurry is 1.49 - 1.51 g / cm 3 , the flow rate of the glaze slurry is 13 - 15 s / 100 mL, the sieve residue of the glaze slurry through a 250 - mesh sieve is 0.5% - 0.7%, and the glazing amount is 440 - 550 g / m 2 ;

[0052] (6) Conducting several times of pattern decoration printing on the primer glaze decoration layer to obtain the pattern decoration layer 4;

[0053] (7) Spraying glaze on the pattern decoration layer to obtain the topcoat glaze decoration layer 5. The process parameters for spraying glaze are as follows: The specific gravity of the glaze slurry is 1.15 - 1.25 g / cm 3 , the flow rate of the glaze slurry is 11 - 13 s / 100 mL, the sieve residue of the glaze slurry through a 250 - mesh sieve is 0.5% - 0.7%, and the glazing amount is 145 - 220 g / m 2 ;

[0054] (8) Apply functional glaze on the surface glaze decoration layer to obtain the functional glaze decoration layer 6, and the process parameters are as follows: the specific gravity of the glaze slurry is 1.4 - 1.5 g / cm 3 , the flow rate of the glaze slurry is 55 - 60 s / 100 mL, and the glaze application amount is 150 - 220 g / m 2 ;

[0055] (9) Fire the semi-finished product decorated through the above steps. The firing temperature is 1180°C - 1200°C, and the firing time is 360 - 480 minutes to obtain the ceramic permeable brick with imitation stone texture, which meets the standard of GB / T 25993-2023 permeable pavement bricks and permeable road slabs.

[0056] In the following preferred embodiments, the mixing step of the surface material blank or the bottom material blank in step (3) or (4) is specifically as follows: the ceramic waste brick particles configured in proportion are successively fed into the mixer and stirred for 2 minutes, then water is added and stirred for 3 minutes to make the surfaces of the ceramic waste brick particles evenly moist, and then the binder is added and stirred for 4 minutes.

[0057] In the following preferred embodiments, the specific steps of pressing and forming in step (3) or (4) are as follows: the uniformly mixed blank is sent to the hopper on the top of the press through the conveyor belt and pressed by the Henglitai 1501 type special press for permeable bricks, and the pressure is set according to the green body strength and water permeability.

[0058] In the following preferred embodiments, the specific steps of drying in step (3) or (4) are as follows: the pressed blank is transported to the roller hearth kiln for drying. The drying temperature is set at 100°C, and the drying time is 10 minutes. The temperature of the dried blank is controlled at 40°C - 45°C to provide the drying temperature for the subsequent bottom glaze. The drying temperature has a great influence on the color and texture of the fired product.

[0059] In the following preferred embodiments, the bottom material blank, by mass fraction, includes the following components: 15 - 25 parts of variegated ceramic waste bricks with a particle size of 6 - 8 mesh, 45 - 55 parts of variegated ceramic waste bricks with a particle size of 8 - 14 mesh, 15 - 25 parts of variegated ceramic waste bricks with a particle size of 14 - 30 mesh, 8 - 12 parts of variegated ceramic waste bricks with a particle size below 30 mesh, 6 - 10 parts of binder, and 3 - 5 parts of water. Further preferably, the bottom material blank, by mass fraction, includes the following components: 20 parts of variegated ceramic waste bricks with a particle size of 6 - 8 mesh, 50 parts of variegated ceramic waste bricks with a particle size of 8 - 14 mesh, 20 parts of variegated ceramic waste bricks with a particle size of 14 - 30 mesh, 10 parts of variegated ceramic waste bricks with a particle size below 30 mesh, 8 parts of binder, and 4 parts of water.

[0060] In the following preferred embodiments, the fabric blank in step (3) comprises the following components in parts by mass: 8 - 12 parts of white ceramic waste bricks with a mesh size of 8 - 14, 30 - 40 parts of white ceramic waste bricks with a mesh size of 14 - 30, 18 - 22 parts of variegated ceramic waste bricks with a mesh size of 8 - 14, 20 - 30 parts of variegated ceramic waste bricks with a mesh size of 14 - 30, 8 - 12 parts of variegated ceramic waste bricks with a mesh size below 30, 6 - 10 parts of binder, and 3 - 5 parts of water. Further preferably, the fabric blank comprises the following components in parts by mass: 10 parts of white ceramic waste bricks with a mesh size of 8 - 14, 35 parts of white ceramic waste bricks with a mesh size of 14 - 30, 20 parts of variegated ceramic waste bricks with a mesh size of 8 - 14, 25 parts of variegated ceramic waste bricks with a mesh size of 14 - 30, 10 parts of variegated ceramic waste bricks with a mesh size below 30, 8 parts of binder, and 4 parts of water.

[0061] In the following preferred embodiments, the binder in step (3) or (4) comprises the following components in parts by mass: 80 - 88 parts of bentonite, 0.8 - 1.2 parts of methyl cellulose, 8 - 12 parts of kaolin, and 4 - 6 parts of albite. Further preferably, the binder comprises the following components in parts by mass: 84 parts of bentonite, 1 part of methyl cellulose, 10 parts of kaolin, and 5 parts of albite.

[0062] In the following preferred embodiments, the base glaze formula for the base glaze decorative layer in step (5) is as follows: in parts by dry weight, it includes 22 - 28 parts of potassium feldspar, 6 - 10 parts of zirconium silicate, 0.1 - 0.3 parts of methyl cellulose, 0.2 - 0.4 parts of sodium tripolyphosphate, 6 - 10 parts of barium carbonate, 6 - 10 parts of kaolin, 12 - 18 parts of albite, 8 - 12 parts of aluminum chloride, 3 - 5 parts of zinc oxide, 5 - 10 parts of quartz, 1 - 3 parts of calcined talc, and 4 - 6 parts of nepheline syenite, and additionally 45 - 55 parts of water. The glazing effect is in a dot pattern distribution. It is necessary to strictly control the glazing parameters and the dotting effect. This process point has a great influence on the water permeability and the product color. Therefore, the glaze spraying cabinet and the glaze line are controlled by a frequency converter. By adjusting the frequency converter parameters, the required glazing parameters and effects can be achieved. Further preferably, the base glaze formula for the base glaze decorative layer is as follows: in parts by dry weight, it includes 25 parts of potassium feldspar, 8 parts of zirconium silicate, 0.2 parts of methyl cellulose, 0.3 parts of sodium tripolyphosphate, 8 parts of barium carbonate, 8 parts of kaolin, 15 parts of albite, 10 parts of aluminum chloride, 4 parts of zinc oxide, 7 parts of quartz, 2 parts of calcined talc, and 5 parts of nepheline syenite, and additionally 50 parts of water.

[0063] In the following preferred embodiments, the specific steps of the pattern decoration in step (6) are as follows: several pattern decoration prints are carried out on the blank of the base glaze decorative layer using a large ink - jet volume digital ink - jet printer, and the nozzle model is the Xaar 2001 model.

[0064] In the following preferred embodiment, the glaze formulation in the surface glaze decorative layer is as follows: based on dry weight parts by mass, it includes 28 - 32 parts of potassium feldspar, 0.1 - 0.3 parts of methyl cellulose, 0.1 - 0.3 parts of sodium tripolyphosphate, 15 - 20 parts of barium carbonate, 8 - 10 parts of dolomite, 13 - 18 parts of albite, 6 - 10 parts of calcined talc, 3 - 5 parts of zinc oxide, 5 - 10 parts of kaolin, and 5 - 10 parts of low-temperature frit, and an additional 45 - 55 parts of water. Further preferably, the glaze formulation in the surface glaze decorative layer is as follows: based on dry weight parts by mass, it includes 30 parts of potassium feldspar, 0.2 parts of methyl cellulose, 0.2 parts of sodium tripolyphosphate, 18 parts of barium carbonate, 9 parts of dolomite, 15 parts of albite, 8 parts of calcined talc, 4 parts of zinc oxide, 8 parts of kaolin, and 8 parts of low-temperature frit, and an additional 50 parts of water. The glazing effect of the surface glaze decorative layer is fan-shaped full coverage, and the glazing parameters need to be strictly controlled, which has a great influence on the product color development.

[0065] In the following preferred embodiment, the functional glaze formulation in the functional glaze decorative layer of step (8) is as follows: based on parts by mass, it includes 66 - 68 parts of dry granule suspending agent, 0.1 - 0.3 parts of methyl cellulose, 10 - 20 parts of water, and 18 - 22 parts of environmentally friendly dry granules. Further preferably, the functional glaze formulation in the functional glaze decorative layer is as follows: based on parts by mass, it includes 66 parts of suspending agent, 0.1 part of methyl cellulose, 16 parts of water, and 18 parts of environmentally friendly dry granules. To enable the stone-textured permeable brick to meet certain performance requirements, the present invention uses a glaze spraying cabinet to apply the functional glaze water, and the glazing effect is dot-shaped distribution.

[0066] In the following preferred embodiment, the specific firing conditions in step (9) are as follows: The semi-finished product decorated through the above steps is sent into a firing kiln for firing. The maximum firing temperature is 1180 °C - 1200 °C, the firing time is 360 - 480 minutes, among which the firing time at the highest temperature stage is 60 minutes, the length of the kiln is 168 meters, and the internal width of the kiln is 2.1 meters.

[0067] The product dimensions, flatness accuracy, and internal quality performance of the ceramic permeable brick imitating stone texture are detected (the main detection indicators are shown in Tables 1 - 3), and it meets the standard of GB / T 25993 - 2023 for permeable pavement bricks and permeable road slabs. Abrasion resistance: The abrasion pit length should not be greater than 35 mm, and skid resistance: The skid resistance BPN value should not be less than 60.

[0068] Table 1 Dimensions (mm)

[0069]

[0070] Table 2 Flexural strength (MPa)

[0071] Flexural strength grade Average value Minimum value of single piece 3.0 ≥3.0 ≥2.4 3.5 ≥3.5 ≥2.8 4.0 ≥4.0 ≥3.2 4.5 ≥4.5 ≥3.6 5.5 ≥5.5 ≥4.4 6.5 ≥6.5 ≥5.2

[0072] Table 3 Permeability coefficient (cm / sec)

[0073] Water permeability grade Water permeability coefficient Grade B ≥1.0×10-2

[0074] Example 1

[0075] A manufacturing method of a ceramic permeable brick imitating stone texture specifically includes the following steps:

[0076] (1) Recycling and homogenization of ceramic waste bricks: Classify ceramic waste bricks according to whiteness and water absorption rate, place waste bricks with different whiteness and water absorption rate separately, and carry out multi-round flipping homogenization on them;

[0077] (2) Crushing the ceramic waste bricks to obtain crushed materials, separately crushing and processing them by a jaw crusher and a hammer crusher, and performing high magnetic iron removal and classification on the particle size of the crushed materials, mainly divided into: 6 - 8 mesh, 8 - 14 mesh, 14 - 30 mesh and below 30 mesh, so as to facilitate the formulation adjustment of product properties such as size, flexural strength, and water permeability;

[0078] (3) Formulate the surface material and the bottom material from the classified ceramic waste brick crushed materials in step (2) according to whiteness and particle size respectively. Mix the bottom material with a binder, control the moisture content of the mixed ingredients at 3.8% - 4.2%, and the viscosity is such that it can be formed into a ball by hand. After mixing evenly, obtain the bottom material blank. The bottom material blank, by mass, includes the following components: 20 parts of variegated ceramic waste bricks of 6 - 8 mesh, 50 parts of variegated ceramic waste bricks of 8 - 14 mesh, 20 parts of variegated ceramic waste bricks of 14 - 30 mesh, 10 parts of variegated ceramic waste bricks below 30 mesh, 8 parts of binder and 4 parts of water. The binder, by mass, includes the following components: 84 parts of bentonite, 1 part of methyl cellulose, 10 parts of kaolin and 5 parts of albite. Press the bottom material blank into shape and dry to obtain the bottom layer blank 1 of the green body;

[0079] (4) Mix the surface material obtained in step (3) with a binder, control the moisture content of the mixed ingredients at 3.8% - 4.2%, and after mixing evenly, obtain the surface material blank. The surface material blank, by mass, includes the following components: 10 parts of white ceramic waste bricks of 8 - 14 mesh, 35 parts of white ceramic waste bricks of 14 - 30 mesh, 20 parts of variegated ceramic waste bricks of 8 - 14 mesh, 25 parts of variegated ceramic waste bricks of 14 - 30 mesh, 10 parts of variegated ceramic waste bricks below 30 mesh, 8 parts of binder and 4 parts of water. The binder, by mass, includes the following components: 84 parts of bentonite, 1 part of methyl cellulose, 10 parts of kaolin and 5 parts of albite. Press the surface material blank into shape and dry to obtain the surface layer blank 2 of the green body;

[0080] (5) Apply a bottom glaze on the surface layer blank of the green body to obtain a bottom glaze decorative layer 3 (as Figure 2 shown), and the process parameters for applying the bottom glaze are: glaze slurry specific gravity 1.49 - 1.51 g / cm 3, the glaze slurry flow rate is 13 - 15 s / 100 mL, the glaze slurry residue on a 250 - mesh sieve is 0.5% - 0.7%, and the glazing amount is 440 - 550 g / m 2 , the base glaze formula is: by dry weight parts, including 25 parts of potassium feldspar, 8 parts of zirconium silicate, 0.2 part of methyl cellulose, 0.3 part of sodium tripolyphosphate, 8 parts of barium carbonate, 8 parts of kaolin, 15 parts of albite, 10 parts of aluminum chloride, 4 parts of zinc oxide, 7 parts of quartz, 2 parts of calcined talc, 5 parts of nepheline syenite and 50 parts of water;

[0081] (6) On the base glaze decorative layer, a large - ink - jet - volume digital ink - jet printer is used for 5 times of pattern decorative printing. The installation order of the ink - jet printer ink is: blue - golden brown - yellow - black - wrapped red, and the nozzle model is Xaar 2001 type, obtaining the pattern decorative layer 4;

[0082] (7) Spraying glaze is carried out on the pattern decorative layer to obtain the top glaze decorative layer 5. The process parameters of spraying glaze are: the glaze slurry specific gravity is 1.15 - 1.25 g / cm 3 , the glaze slurry flow rate is 11 - 13 s / 100 mL, the glaze slurry residue on a 250 - mesh sieve is 0.5% - 0.7%, and the glazing amount is 145 - 220 g / m 2 , the top glaze formula is: by dry weight parts, including 30 parts of potassium feldspar, 0.2 part of methyl cellulose, 0.2 part of sodium tripolyphosphate, 18 parts of barium carbonate, 9 parts of dolomite, 15 parts of albite, 8 parts of calcined talc, 4 parts of zinc oxide, 8 parts of kaolin and 8 parts of low - temperature frit, and then an additional 50 parts of water are added;

[0083] (8) Spraying functional glaze is carried out on the top glaze decorative layer to obtain the functional glaze decorative layer 6. Its process parameters are: the glaze slurry specific gravity is 1.4 - 1.5 g / cm 3 , the glaze slurry flow rate is 55 - 60 s / 100 mL, the glazing amount: 150 - 220 g / m 2 , the functional glaze formula is: by parts by mass, including 66 parts of dry - particle suspending agent, 0.1 part of methyl cellulose, 16 parts of water and 18 parts of environmental - protection dry particles;

[0084] (9) The semi - finished product decorated through the above steps is fired. The highest firing temperature is 1180℃ - 1200℃, and the firing time is 360 - 480 minutes, among which the firing time at the highest - temperature stage is 60 minutes, obtaining the ceramic permeable brick with a stone - like texture.

[0085] For this ceramic permeable brick, the thickness of the base layer of the green body is about 50 mm, the thickness of the surface layer of the green body is about 9 mm, the thickness of the base glaze decorative layer is about 0.15 mm, the thickness of the top glaze decorative layer is about 0.05 mm, and the thickness of the functional glaze decorative layer is about 0.6 mm.

[0086] Comparative Example 1

[0087] Same as Example 1, except that in step (5), the equipment and process used in traditional bell jar glazing and water jet glazing are adopted.

[0088] Compared with Comparative Example 1, in Example 1, the underglaze is dot-sprayed by a centrifugal glazing machine (such as Figure 2 ), while ensuring that the pattern decorative layer is closer to the color and texture of natural stone, and at the same time ensuring that the water permeability coefficient ≥ 1.0×10 -2 .

[0089] Comparative Example 2

[0090] Same as Example 1, except that step (8) is missing, and the thickness of the top glaze decorative layer is the sum of the thicknesses of the top glaze decorative layer and the functional glaze decorative layer in Example 1.

[0091] The comparison of the anti-slip performance between Example 1 and Comparative Example 2 is shown in Table 2:

[0092] Table 2

[0093] Without functional glaze decorative layer (Comparative Example 2) With functional glaze decorative layer (Example 1) BPN > 50 BPN > 60

[0094] Example 2

[0095] Same as Example 1, except that:

[0096] In step (3), the base material blank, by mass parts, comprises the following components: 15 parts of variegated ceramic waste bricks with a particle size of 6 - 8 mesh, 55 parts of variegated ceramic waste bricks with a particle size of 8 - 14 mesh, 15 parts of variegated ceramic waste bricks with a particle size of 14 - 30 mesh, 12 parts of variegated ceramic waste bricks with a particle size below 30 mesh, 6 parts of binder and 5 parts of water. The surface material blank, by mass parts, comprises the following components: 8 parts of white ceramic waste bricks with a particle size of 8 - 14 mesh, 40 parts of white ceramic waste bricks with a particle size of 14 - 30 mesh, 18 parts of variegated ceramic waste bricks with a particle size of 8 - 14 mesh, 30 parts of variegated ceramic waste bricks with a particle size of 14 - 30 mesh, 8 parts of variegated ceramic waste bricks with a particle size below 30 mesh, 10 parts of binder and 3 parts of water. The binder in step (3) or (4), by mass parts, comprises the following components: 80 parts of bentonite, 0.8 part of methyl cellulose, 8 parts of kaolin and 4 parts of albite.

[0097] The formula of the underglaze in the underglaze decorative layer in step (5) is: by dry weight mass parts, it comprises 22 parts of potassium feldspar, 6 parts of zirconium silicate, 0.1 part of methyl, 0.2 part of trimer, 6 parts of barium carbonate, 6 parts of kaolin, 12 parts of albite, 8 parts of aluminum chloride, 3 parts of zinc oxide, 5 parts of quartz, 1 part of calcined talc and 4 parts of nepheline syenite, and additionally 45 parts of water.

[0098] In step (7), the glaze formulation for the surface glaze layer is as follows: by dry weight parts, it includes 32 parts of potassium feldspar, 0.3 part of methyl, 0.3 part of trimer, 20 parts of barium carbonate, 10 parts of dolomite, 18 parts of albite, 10 parts of calcined talc, 5 parts of zinc oxide, 10 parts of kaolin, 10 parts of low-temperature frit, and an additional 55 parts of water.

[0099] In step (8), the glaze formulation for the functional glaze layer is as follows: by parts by mass, it includes 66 parts of dry granule suspending agent, 0.1 part of methyl cellulose, 16 parts of water, and 18 parts of environmentally friendly dry granules.

[0100] Example 3

[0101] Same as Example 1, the differences are as follows:

[0102] In step (3), the base material blank, by parts by mass, includes the following components: 25 parts of variegated ceramic waste bricks with a particle size of 6 - 8 mesh, 45 parts of variegated ceramic waste bricks with a particle size of 8 - 14 mesh, 25 parts of variegated ceramic waste bricks with a particle size of 14 - 30 mesh, 8 parts of variegated ceramic waste bricks with a particle size below 30 mesh, 10 parts of binder, and 3 parts of water. The surface material blank, by parts by mass, includes the following components: 12 parts of white ceramic waste bricks with a particle size of 8 - 14 mesh, 30 parts of white ceramic waste bricks with a particle size of 14 - 30 mesh, 22 parts of variegated ceramic waste bricks with a particle size of 8 - 14 mesh, 20 parts of variegated ceramic waste bricks with a particle size of 14 - 30 mesh, 12 parts of variegated ceramic waste bricks with a particle size below 30 mesh, 6 parts of binder, and 5 parts of water. The binder in step (3) or (4), by parts by mass, includes the following components: 88 parts of bentonite, 1.2 parts of methyl, 12 parts of kaolin, and 6 parts of albite.

[0103] In step (5), the glaze formulation for the base glaze layer is as follows: by parts by mass, it includes 28 parts of potassium feldspar, 10 parts of zirconium silicate, 0.3 part of methyl, 0.4 part of trimer, 10 parts of barium carbonate, 10 parts of kaolin, 18 parts of albite, 12 parts of aluminum chloride, 5 parts of zinc oxide, 10 parts of quartz, 3 parts of calcined talc, and 6 parts of nepheline syenite, and an additional 55 parts of water.

[0104] In step (7), the glaze formulation for the surface glaze layer is as follows: by parts by mass, it includes 28 parts of potassium feldspar, 0.1 part of methyl cellulose, 0.1 part of sodium tripolyphosphate, 15 parts of barium carbonate, 8 parts of dolomite, 13 parts of albite, 6 parts of calcined talc, 3 parts of zinc oxide, 5 parts of kaolin, 5 parts of low-temperature frit, and an additional 45 parts of water.

[0105] In step (8), the glaze formulation for the functional glaze layer is as follows: by parts by mass, it includes 68 parts of dry granule suspending agent, 0.1 part of methyl cellulose, 10 parts of water, and 22 parts of environmentally friendly dry granules.

[0106] The description of the above embodiments is only used to help understand the technical solution and its core idea of the present invention. It should be noted that for those skilled in the art of this technology, without departing from the principle of the present invention, several improvements and modifications can be made to the present invention, and these improvements and modifications also fall within the protection scope of the claims of the present invention.

Claims

1. A ceramic permeable brick with an imitation stone texture, characterized in that, From bottom to top, it successively includes a green body base material layer, a green body surface material layer, an underglaze decoration layer, a pattern decoration layer, a glaze decoration layer, and a functional glaze decoration layer. When the ratio of the nominal length to the nominal thickness of the ceramic permeable brick is less than or equal to 4 and it is a permeable pavement brick, the splitting tensile strength ≥ 3.0 MPa, and the water permeability coefficient is greater than or equal to 1.0×10 -2 cm / s; when the ratio of the nominal length to the nominal thickness of the ceramic permeable brick is greater than 4 and it is a permeable road slab, the flexural strength ≥ 3.0 MPa, and the water permeability coefficient is greater than or equal to 1.0×10 -2 cm / s; the formula of the underglaze in the underglaze decoration layer is: by dry weight in parts by mass, including 22 - 28 parts of potassium feldspar, 6 - 10 parts of zirconium silicate, 0.1 - 0.3 parts of methyl cellulose, 0.2 - 0.4 parts of sodium tripolyphosphate, 6 - 10 parts of barium carbonate, 6 - 10 parts of kaolin, 12 - 18 parts of albite, 8 - 12 parts of aluminum chloride, 3 - 5 parts of zinc oxide, 5 - 10 parts of quartz, 1 - 3 parts of burnt talc, and 4 - 6 parts of nepheline syenite, and then an additional 45 - 55 parts of water are added. The underglaze is sprayed in a dot pattern using a spin coater; the formula of the glaze in the glaze decoration layer is: by dry weight in parts by mass, including 28 - 32 parts of potassium feldspar, 0.1 - 0.3 parts of methyl cellulose, 0.1 - 0.3 parts of sodium tripolyphosphate, 15 - 20 parts of barium carbonate, 8 - 10 parts of dolomite, 13 - 18 parts of albite, 6 - 10 parts of burnt talc, 3 - 5 parts of zinc oxide, 5 - 10 parts of kaolin, and 5 - 10 parts of low-temperature frit, and then an additional 45 - 55 parts of water are added; the formula of the functional glaze in the functional glaze decoration layer is: by mass in parts, including 62 - 70 parts of dry particle suspending agent, 0.1 - 0.3 parts of methyl cellulose, 13 - 20 parts of water, and 15 - 18 parts of ceramic dry particles.

2. The ceramic permeable brick with imitation stone texture according to claim 1, characterized in that, The surface glaze decoration layer is prepared by the following steps: spraying glaze on the pattern decoration layer to obtain the surface glaze decoration layer. The process parameters of spraying glaze are as follows: the specific gravity of the glaze slurry is 1.15 - 1.25 g / cm 3 , the flow rate of the glaze slurry is 11 - 13 s / 100 mL, the sieve residue of the glaze slurry through a 250-mesh sieve is 0.5% - 0.7%, and the glaze application amount is 145 - 220 g / m 2 .

3. The manufacturing method of the ceramic permeable brick with artificial stone texture according to claim 1, characterized in that, The steps include: (1) Crush the waste ceramic bricks to obtain crushed materials, remove iron from the crushed materials and classify them according to their particle size, which are: 6-8 mesh, 8-14 mesh, 14-30 mesh and below 30 mesh; (2) The crushed ceramic waste brick particles classified in step (1) are respectively prepared into a surface material and a base material according to whiteness and particle size, the base material is mixed with a binder, the moisture content of the mixed ingredients is controlled at 3.8% to 4.2%, and the base material blank is obtained after being evenly mixed, and the base material blank is pressed into a blank base material layer; (3) mixing the fabric obtained in step (2) with a binder, controlling the moisture content of the mixed ingredients to be 3.8% to 4.2%, mixing evenly to obtain a fabric blank, and pressing the fabric blank into a blank fabric layer; (4) Apply the base glaze on the green body fabric layer to obtain the base glaze decorative layer. The process parameters for applying the base glaze are as follows: the specific gravity of the glaze slurry is 1.49 - 1.51 g / cm 3 , the flow rate of the glaze slurry is 13 - 15 s / 100mL, the sieve residue of the glaze slurry through a 250-mesh sieve is 0.5% - 0.7%, and the glaze application amount is 440 - 550 g / m 2 ; (5) Printing a pattern decoration several times on the base glaze decoration layer to obtain a pattern decoration layer; (6) Spray and apply glaze on the pattern decoration layer to obtain a surface glaze decoration layer. The process parameters for spray glazing are as follows: the specific gravity of the glaze slurry is 1.15 - 1.25 g / cm 3 , the flow rate of the glaze slurry is 11 - 13 s / 100mL, the sieve residue of the glaze slurry through a 250-mesh sieve is 0.5% - 0.7%, and the glaze application amount is 145 - 220 g / m 2 ; (7) Apply the functional glaze on the surface glaze decoration layer to obtain the functional glaze decoration layer. The process parameters are as follows: the specific gravity of the glaze slurry is 1.4 - 1.5 g / cm 3 , the flow rate of the glaze slurry is 55 - 60 s / 100 mL, and the glaze application amount is 150 - 220 g / m 2 ; (8) The semi-finished product decorated in the above steps is fired at a temperature of 1180° C. to 1200° C. for 360 to 480 minutes to obtain the ceramic permeable brick with the imitation stone texture.

4. The manufacturing method according to claim 3, characterized in that, The base material blank described in step (2) comprises the following components, calculated by weight: 15-25 parts of 6-8 mesh variegated ceramic waste bricks, 45-55 parts of 8-14 mesh variegated ceramic waste bricks, 15-25 parts of 14-30 mesh variegated ceramic waste bricks, 8-12 parts of 30 mesh variegated ceramic waste bricks, 6-10 parts of binder and 3-5 parts of water; the surface material blank described in step (3) comprises the following components, calculated by weight: 8-12 parts of 8-14 mesh white ceramic waste bricks, 30-40 parts of 14-30 mesh white ceramic waste bricks, 18-22 parts of 8-14 mesh variegated ceramic waste bricks, 20-30 parts of 14-30 mesh variegated ceramic waste bricks, 8-12 parts of 30 mesh variegated ceramic waste bricks, 6-10 parts of binder and 3-5 parts of water.

5. The manufacturing method according to claim 3 or 4, characterized in that, The binder described in step (2) or (3) comprises the following components, calculated by weight: 80-88 parts of bentonite, 0.8-1.2 parts of methyl cellulose, 8-12 parts of kaolin and 4-6 parts of albite.

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