Ceramic tile with concave-convex textures and preparation method thereof

Abstract

The invention belongs to the technical field of ceramic tiles, and particularly discloses a ceramic tile with concave-convex textures and a preparation method of the ceramic tile. The ceramic tile sequentially comprises a green body layer, a mold ink texture layer formed by printing hydrophobic mold ink, a mold cover glaze layer formed by hydrophilic mold cover glaze, a pattern layer, a glue layer, a dry powder glaze layer and a protective glaze layer which is formed by water-based protective glaze and comprises a penetrating agent, the inorganic glaze components in the glue layer and the protective glaze layer are the same as the dry powder glaze in composition. According to the invention, a digital glaze mold process is combined with glue printing and positioning, and is matched with the improvement of a glue ink formula and the design of water-based protective glaze, so that the final ceramic tile has a fine concave-convex texture effect which is closer to a multi-dimensional stereoscopic effect of natural stone; and the problems of uneven glaze orange peel, inconsistent color development, poor transparency, insufficient glaze layer thickness, poor glaze physical property, glaze stripping and falling of raised parts, poor antifouling and wear resistance and the like which are easy to occur are solved.

Description

Technical Field

[0001] The invention belongs to the technical field of ceramic tiles, and in particular relates to a ceramic tile with a concave-convex texture and a preparation method thereof. Background Art

[0002] With the continuous development of the economy and the improvement of equipment, materials and technology, people's demand for ceramic tiles is also changing. One of them is to hope that ceramic tiles can simulate the effect of the undulating texture of natural stone. At present, there are mainly the following methods for producing ceramic tiles with undulating effect: one is to use sinking and fine carving functional ink to spread the surface glaze to form a undulating texture; the other is to use digital glaze to spread the surface glaze to form a digital mold product; and some are to use screen printing glue combined with dry particles to make the glaze surface produce a raised glaze effect.

[0003] However, both the current methods of fine carving and sinking and digital molds can only produce products with sunken surfaces and fine textures; and although the method of screen printing glue combined with dry particles can form a raised glaze effect, the fineness is poor. Summary of the invention

[0004] The purpose of the present invention is to solve the deficiencies of the prior art and provide a ceramic tile with a concave-convex texture effect and a preparation method thereof. Based on this, the first aspect of the present invention provides a ceramic tile with a concave-convex texture, which sequentially comprises a body layer, a mold ink texture layer, a mold surface glaze layer, a pattern layer, a glue layer, a dry powder glaze layer and a protective glaze layer; the mold ink texture layer is formed by printing a hydrophobic mold ink, and the mold surface glaze layer is formed by a hydrophilic mold surface glaze; The dry powder glaze layer is formed by dry powder glaze; the glue layer is formed by printing with glue ink, and the glue ink includes a first inorganic glaze component; the protective glaze layer is formed by aqueous protective glaze, and the aqueous protective glaze includes a second inorganic glaze component and a penetrant; the composition of the first inorganic glaze component and the second inorganic glaze component are the same as the composition of the dry powder glaze; the composition refers to the type and content of chemical substances (that is, the type and content of chemical substances are the same).

[0005] The present application first applies hydrophobic mold ink (i.e., mold ink with hydrophobicity, any mold ink with hydrophobicity can be used in the scheme of the present invention) and hydrophilic mold glaze (i.e., mold glaze with hydrophilicity, any mold glaze with hydrophilicity can be used in the scheme of the present invention) in sequence, so that the two are repelled, thereby forming a concave effect; then, the glue ink is applied in a printing manner, combined with dry particle glaze, to form a convex effect; combined with the above-mentioned digital mold process and glue positioning process, finally a ceramic tile with fine concave-convex texture is obtained; moreover, the present invention realizes the combination of two processes with different concave-convex effects, and the final product has a stronger three-dimensional sense, a larger concave-convex drop, and is closer to the multi-dimensional three-dimensional effect formed by natural stone. On this basis, the present invention also makes a special design for the glue ink and the water-based protective glaze, so that the inorganic glaze composition in the two is the same as the dry granular glaze, thereby ensuring that during the firing process, after the organic components in the glue ink volatilize, the remaining inorganic components can be fully combined with the dry powder glaze, avoiding the problem of glaze surface defects such as orange peel unevenness and poor physical properties caused by the large gaps left after the organic components volatilize; on the other hand, the inorganic glaze composition in the water-based protective glaze of the present invention is the same as the dry granular glaze. Combined with another specially set penetrant in the water-based protective glaze of the present invention (which can improve the wettability of the water-based protective glaze for the dry powder glaze and make the liquid more easily penetrate into the solid), the above-mentioned effects jointly ensure that the color and transparency of the raised area and the sunken area are consistent. In addition, because the water-based protective glaze used in the present invention includes a penetrant, the wettability of the dry powder glaze can be kept consistent with other positions, solving the problem of glaze peeling and falling off of the raised parts in the glue positioning process.

[0006] It should be noted that if the water-based protective glaze of the present invention is not sprayed after the dry powder glaze is applied, on the one hand, there will be problems of inconsistent color development. On the other hand, the dry granular glaze has less internal moisture and is inconsistent with other positions when drying, which can easily cause problems such as glaze peeling and dry granules falling off. In addition, since the glue ink used is mostly organic, after firing, the organic components will evaporate before the glaze melts, and the gaps and vacancies formed are large, which will cause the glaze surface to be uneven, and the internal voids are prone to form pinholes after firing, affecting the anti-fouling performance of the product. If a digital protective glaze is used instead of the water-based protective glaze in the present invention, there will be a situation where the glaze is not thick enough, and most of its organic matter will evaporate after firing, resulting in a thin glaze layer and poor thickness. For light-colored pattern products, it will bring technical problems such as poor wear resistance and anti-fouling performance. Therefore, compared with the above situation, the water-based protective glaze of the present invention is thicker, and at the same time improves the glaze texture, anti-fouling and wear resistance and other glaze physical properties in the non-raised area.

[0007] In some preferred embodiments, the above-mentioned dry powder glaze includes, by mass percentage: Al2O3 16.30%-18.56%, SiO2 48.82%-52.34%, K2O 1.02%-3.65%, Na2O 1.24%-3.86%, CaO 0.85%-1.95%, MgO 0.75%-2.01%, BaO 8.57%-11.45%, ZnO 3.24%-6.35%, SrO 2.14%-4.25%, and B2O3 4.32%-6.12%. The dry powder glaze of the above composition has a matte luster after firing, and has a high high-temperature viscosity, which ensures that the previously accumulated protrusions will not collapse and deform after firing, and maintains the desired effect; at the same time, it has a wide firing range, which ensures that the exhaust can be smooth under the premise of high high-temperature viscosity after firing, and the glaze layer contains fewer pores, so that the glaze surface has better anti-fouling and wear-resistant properties, and still has good transparency under the premise of a thicker glaze layer in the protruding parts. The present invention can also use other dry powder glazes to implement the scheme, but the effect is different from the specific dry powder glaze here, which is manifested in that some other dry powder glazes have good glaze effects but are not wear-resistant, and some other dry powder glazes have good wear resistance but poor glaze texture.

[0008] In some preferred embodiments, the above-mentioned water-based protective glaze includes, by weight: 50-57 parts of the second inorganic glaze component, 4-8 parts of the penetrant (optionally polyethylene glycol), 2-4 parts of water-based glue (optionally Qiantao 9022A), and 35-40 parts of water. The water-based protective glaze of the present invention can also increase the water-based glue component, which can work together with the penetrant to easily penetrate into the dry powder glaze, ensuring the adhesion of the dry powder glaze and making it more solid; while the penetrant quickly wets the inside of the dry powder glaze and cooperates with the glue to bond and fix, so that the present invention has the characteristics of the thickness of the protective glaze layer and good glaze physical properties, while reducing the problem of easy falling off and peeling of the dry powder glaze.

[0009] In some preferred embodiments, the glue ink comprises, by weight: 15-23 parts of acrylic polymer, 2-10 parts of dispersant, 40-55 parts of organic solvent, and 15-40 parts of the first inorganic glaze component. Among them, the acrylic polymer has strong viscosity. After being made into glue ink, it can be printed through the printer nozzle. Its weight is preferably selected as 15-23 parts, so that after being dissolved in the organic solvent, it maintains high viscosity and has suitable fluidity; when the glue ink is printed, it can effectively bond the dry powder glaze to ensure that it has an ideal convex shape after firing; the dispersant is mainly used to ensure the flow of the glue ink so that it can be smoothly printed from the printer nozzle, and methyl amyl alcohol or fatty acid polyethylene glycol can be selected; the organic solvent mainly dissolves the acrylic polymer and makes the glue ink dispersed evenly and dissolved completely without reducing its viscosity. In order to ensure smooth printing, ethylene glycol or trichloroethylene can be selected.

[0010] A second aspect of the present invention provides a method for preparing the above-mentioned ceramic tile with a concave-convex texture, comprising the following steps: The hydrophobic mold ink is printed on the green body layer, and then the hydrophilic mold glaze is sprayed, followed by printing the pattern layer ink (for subsequent firing to form the pattern layer) and the glue ink in sequence; then the dry powder glaze is applied, followed by spraying the aqueous protective glaze, and firing to obtain the ceramic tile.

[0011] The printing grayscale value of the hydrophobic mold ink is 10%-50%, and the printing volume is 10 g / m 2 -30 g / m 2 The amount of the hydrophilic mold glaze applied is 500 g / m 2 -600 g / m 2 The printing grayscale value of the above glue ink is 10%-70%, and the printing volume is 50 g / m 2 -120 g / m 2 The amount of dry powder glaze applied is 100 g / m 2 -500 g / m 2 The specific gravity of the above-mentioned water-based protective glaze is 1.28 g / mL-1.32 g / mL, and the application amount is 150 g / m 2 -180 g / m 2 .

[0012] The sintering temperature is 1180°C-1190°C and the sintering time is 45 min-60 min. The moisture content of the green body layer is not more than 0.4% by mass, and the strength is 1.8 MPa-2.4 MPa. The green body layer can be prepared by a press, and maintaining the moisture content and strength is more conducive to subsequent processing.

[0013] After applying the dry powder glaze, the dry powder glaze that is not adhered by the glue ink is removed, and then the water-based protective glaze is sprayed. The removal method can be suction removal, and the sucked dry powder glaze can be reused.

[0014] The specific process of the above preparation method can be as follows: The dried green body layer is sent to the glaze line, and the first inkjet machine prints the hydrophobic mold ink according to the designed texture pattern (natural stone texture can be replicated), and forms concave texture effects of different depths in combination with the subsequent hydrophilic mold glaze according to different gray values; the green body layer printed with the hydrophobic mold ink enters the mold glaze spraying equipment for spraying the hydrophilic mold glaze, and the two form a repulsion, thereby forming a concave effect, thereby forming a glaze with a mold undulating effect, and then enters the second inkjet machine to print the pattern layer ink, print the color texture to form the above pattern layer (the color texture can be selected according to the marble material); then enter ... and print the color texture to form the above pattern layer. Three inkjet machines are used to print the above-mentioned glue ink, and the above-mentioned glue ink is printed according to the designed texture to print out the required graphics; then the dry powder glaze applying equipment is used to apply the above-mentioned dry powder glaze, and then the dry powder glaze absorption equipment is used to absorb the dry powder glaze that is not stuck by the glue, leaving the dry powder glaze with a certain texture pattern (after subsequent firing, a raised effect according to the design can be formed, and the sucked dry powder can be recycled and reused); then the protective glaze spraying equipment is used to spray the above-mentioned water-based protective glaze; after the above-mentioned processes, the ceramic tile is fired in a roller kiln to finally obtain the ceramic tile with a concave-convex texture and the above-mentioned various characteristics of the present invention.

[0015] The beneficial effects of the present invention are as follows: the present invention combines the digital glaze mold process with glue printing positioning, cooperates with the improvement of the glue ink formula and the design of the water-based protective glaze, so that the final ceramic tile has a fine concave-convex texture effect, and the concave-convex drop is larger, the three-dimensional sense is stronger, and it is closer to the multi-dimensional three-dimensional effect of natural stone; and solves the technical problems that are easy to occur, such as uneven glaze orange peel, inconsistent color, poor transparency, insufficient glaze layer thickness, poor glaze physical properties, glaze peeling on raised parts, dry powder glaze shedding, and poor anti-fouling and wear resistance. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 Shown is a photograph of a ceramic tile prepared in Example 1; Figure 2 Shown is a photograph of the ceramic tile prepared in Comparative Example 1. DETAILED DESCRIPTION

[0017] The following will be combined with the embodiments and drawings to clearly and completely describe the concept and technical effects of the present invention, so as to fully understand the purpose, scheme and effect of the present invention. It should be noted that the embodiments and features in the embodiments of the present invention can be combined with each other without conflict.

[0018] Example 1 A ceramic tile with a concave-convex texture, comprising a body layer, a mold ink texture layer, a mold surface glaze layer, a pattern layer, a glue layer, a dry powder glaze layer and a protective glaze layer in sequence; the mold ink texture layer is formed by printing a hydrophobic mold ink (Taolisi Ceramic Glaze Color Co., Ltd., No. CNX00520), and the mold surface glaze layer is formed by a hydrophilic mold surface glaze, and the hydrophilic mold surface glaze includes, by mass percentage: Al2O3: 23.15%, SiO2: 56.14%, K2O: 2.18%, Na2O: 3.1 4%, CaO: 0.89%, MgO: 1.25%, ZnO: 2.36%, BaO: 3.24%, ZrO2: 7.21%, and the rest are trace impurities and reduction; the dry powder glaze layer is formed by dry powder glaze; the glue layer is formed by printing with glue ink, and the glue ink includes a first inorganic glaze component; the protective glaze layer is formed by aqueous protective glaze, and the aqueous protective glaze includes a second inorganic glaze component and a penetrant (polyethylene glycol); the compositions of the first inorganic glaze component and the second inorganic glaze component are the same as those of the dry powder glaze.

[0019] The dry powder glaze includes, by mass percentage, Al2O317.43%, SiO250.58%, K2O 2.33%, Na2O 2.55%, CaO 1.4%, MgO 1.38%, BaO 10.01%, ZnO 4.79%, SrO 3.19%, B2O35.22%; the rest are trace impurities and can be reduced as appropriate.

[0020] The water-based protective glaze includes, by weight: 53.5 parts of the second inorganic glaze component, 6 parts of penetrant (polyethylene glycol), 3 parts of water-based glue (Jiangxi Qiantao New Materials Co., Ltd., No. 9022A), and 37.5 parts of water. The glue ink includes, by weight: 19 parts of acrylic polymer (polymethyl acrylate, Hubei Yunmei Technology Co., Ltd., model: CAS: 9003-21-8), 6 parts of dispersant (methyl amyl alcohol), 43 parts of organic solvent (ethylene glycol), and 27.5 parts of the first inorganic glaze component.

[0021] The method for preparing the ceramic tile having a concave-convex texture comprises the following steps: The dried green body layer (water content of 0.3% by mass and strength of 2.0 MPa) was fed into the glaze line for the first inkjet machine to print the hydrophobic mold ink according to the designed texture pattern, with a grayscale value of 30% and a print volume of 20 g / m2 (Combined with the subsequent hydrophilic mold glaze to form concave texture effects of different depths); The green body layer printed with the hydrophobic mold ink is fed into the mold glaze spraying device for spraying the hydrophilic mold glaze (the application amount is 550 g / m 2 ), the two repel each other, thus forming a concave effect, thereby forming a glaze surface with a mold undulating effect, and then entering the second inkjet machine to print the pattern layer ink, printing the color texture to form the above-mentioned pattern layer; Then enter the third inkjet machine to print the above glue ink (grayscale value is 50%, print volume is 100g / m 2 ), the glue ink is printed according to the designed texture to print the required graphics; then it enters the dry powder glaze application equipment to apply the dry powder glaze (the application amount is 300 g / m 2 ), and then enter the dry powder glaze suction equipment to suck away the dry powder glaze that is not stuck by the glue, leaving the dry powder glaze with a certain texture pattern (after subsequent firing, it can form a convex effect according to the design, and the sucked dry powder can be recycled and reused); then enter the protective glaze spraying equipment to spray the above-mentioned water-based protective glaze (the specific gravity of the above-mentioned water-based protective glaze is 1.3 g / mL, and the application amount is 160 g / m 2 ); After the above process, it enters the roller kiln for firing at a temperature of 1185°C for 50 min, and finally obtains the above ceramic tile with concave-convex texture; its photo is shown in FIG. Figure 1 shown.

[0022] Example 2 A ceramic tile with a concave-convex texture, which differs from Example 1 in that: the first inorganic glaze component in the glue ink is 15 parts; the rest is the same as Example 1.

[0023] Example 3 A ceramic tile with a concave-convex texture, which differs from Example 1 in that: the first inorganic glaze component in the glue ink is 40 parts; the rest is the same as Example 1.

[0024] Example 4 A ceramic tile with a concave-convex texture, which differs from Example 1 in that the grayscale value of the printing glue ink is 10%; the rest is the same as Example 1.

[0025] Example 5 A ceramic tile with a concave-convex texture, which differs from Example 1 in that the grayscale value of the printing glue ink is 50%; the rest is the same as Example 1.

[0026] Example 6 A ceramic tile with a concave-convex texture, which is different from Example 1 in that: the penetrant in the water-based protective glaze is 4 parts; the rest is the same as Example 1.

[0027] Example 7 A ceramic tile with a concave-convex texture, which is different from Example 1 in that: the penetrant in the water-based protective glaze is 8 parts; the rest is the same as Example 1.

[0028] Example 8 A ceramic tile with a concave-convex texture, which differs from Example 1 in that: the water-based glue in the water-based protective glaze is 2 parts; the rest is the same as Example 1.

[0029] Example 9 A ceramic tile with a concave-convex texture, which differs from Example 1 in that: the water-based glue in the water-based protective glaze is 4 parts; the rest is the same as Example 1.

[0030] Comparative Example 1 A ceramic tile, which differs from Example 1 in that: the glue ink does not contain the first inorganic glaze component; the rest is the same as Example 1; its photo is as shown Figure 2 shown.

[0031] Comparative Example 2 A ceramic tile, which differs from Example 1 in that the grayscale value of the printing glue ink is 8%; the rest is the same as Example 1.

[0032] Comparative Example 3 A ceramic tile, which is different from Example 1 in that the grayscale value of the printing glue ink is 75%; the rest is the same as Example 1.

[0033] Comparative Example 4 A ceramic tile, which is different from Example 1 in that: the amount of penetrant in the water-based protective glaze is 2 parts; the rest is the same as Example 1.

[0034] Comparative Example 5 A ceramic tile, which is different from Example 1 in that: the penetrant in the water-based protective glaze is 10 parts; the rest is the same as Example 1.

[0035] Comparative Example 6 A ceramic tile, which is different from Example 1 in that the water-based protective glaze does not include water-based glue; the rest is the same as Example 1.

[0036] Comparative Example 7 A ceramic tile, which differs from Example 1 in that: the dry powder glaze includes, by mass percentage, Al2O3 19.06%, SiO2 60.34%, K2O 2.66%, Na2O 3.24%, CaO 4.84%, MgO 1.75%, BaO 5.55%; the rest are trace impurities and are reduced as appropriate. The first inorganic glaze component and the second inorganic glaze component are consistent with Example 1, and include, by mass percentage, Al2O3 17.43%, SiO2 50.58%, K2O 2.33%, Na2O 2.55%, CaO 1.4%, MgO 1.38%, BaO 10.01%, ZnO 4.79%, SrO 3.19%, B2O 3 5.22%; the rest are trace impurities and are reduced as appropriate. The rest is also the same as Example 1.

[0037] Effect detection test The judgment of the product surface effect and concave-convex three-dimensional effect is mainly through visual inspection. The heavy texture of the glaze is mainly felt by touch. The main test items for physical properties are anti-fouling performance and wear resistance, and the test basis is GB / T4100-2015, Appendix G of "Ceramic Tiles" Dry-pressed Ceramic Tiles.

[0038] The test results of each embodiment and comparative example are shown in Table 1.

[0039] Table 1 Comparative Example 1: The glue ink does not contain inorganic glaze ingredients. After firing, the gaps left by the decomposition and volatilization of the organic glue in the raised parts are not filled with enough inorganic matter, resulting in the orange peel of the raised parts and the thickness of this part. Comparative Example 2: The glue ink printing volume is not enough, resulting in insufficient height of the raised parts, and the concave-convex effect cannot be achieved. Comparative Example 3: The glue ink printing volume is too much, there are too many organic substances, and the drainage is difficult. After firing, the raised parts have problems such as orange peel and pits. Comparative Example 4: The amount of penetrant glaze in the protective glaze is small, resulting in the phenomenon of falling off and peeling of the dry powder glaze during firing. Comparative Example 5: The protective glaze contains too much penetrant, and the organic substances decompose after firing, resulting in orange peel and uneven glaze surface. Comparative Example 6: The protective glaze does not contain water-based glue, and the dry powder glaze falls off during the firing process, resulting in rough and uneven raised parts, easy to get dirty and other problems. Comparative Example 7: A relatively conventional dry powder glaze was selected. After firing, it reacted with the inorganic substances in the glue ink and the inorganic substances in the protective glaze to form more glass phases and fewer crystal types, resulting in poor performance.

[0040] The above is only a preferred embodiment of the present invention. The present invention is not limited to the above implementation. As long as the technical effect of the present invention is achieved by the same means, it should belong to the protection scope of the present invention. Within the protection scope of the present invention, its technical scheme and / or implementation method can have various modifications and changes.

Claims

1. A ceramic tile with a concave-convex texture, characterized in that: The mold ink texture layer includes a body layer, a mold surface glaze layer, a pattern layer, a glue layer, a dry powder glaze layer and a protective glaze layer in sequence; the mold ink texture layer is formed by printing a hydrophobic mold ink, and the mold surface glaze layer is formed by a hydrophilic mold surface glaze; The dry powder glaze layer is formed by dry powder glaze; the glue layer is formed by printing with glue ink, and the glue ink includes a first inorganic glaze component; the protective glaze layer is formed by aqueous protective glaze, and the aqueous protective glaze includes a second inorganic glaze component and a penetrant; the compositions of the first inorganic glaze component and the second inorganic glaze component are the same as the composition of the dry powder glaze.

2. The ceramic tile according to claim 1, characterized in that: The dry powder glaze comprises, by mass percentage, Al2O3 16.30%-18.56%, SiO2 48.82%-52.34%, K2O 1.02%-3.65%, Na2O 1.24%-3.86%, CaO0.85%-1.95%, MgO 0.75%-2.01%, BaO 8.57%-11.45%, ZnO 3.24%-6.35%, SrO 2.14%-4.25%, and B2O3 4.32%-6.12%.

3. The ceramic tile according to claim 1, characterized in that: The water-based protective glaze comprises, by weight: 50-57 parts of the second inorganic glaze component, 4-8 parts of the penetrant, 2-4 parts of water-based glue, and 35-40 parts of water.

4. The ceramic tile according to claim 1, characterized in that: The glue ink comprises, by weight: 15-23 parts of acrylic polymer, 2-10 parts of dispersant, 40-55 parts of organic solvent, and 15-40 parts of the first inorganic glaze component.

5. A method for preparing a ceramic tile according to any one of claims 1 to 4, characterized in that: The following steps are involved: The hydrophobic mold ink is printed on the green body layer, and then the hydrophilic mold glaze is sprayed, followed by printing the pattern layer ink and the glue ink in sequence; then the dry powder glaze is applied, and then the aqueous protective glaze is sprayed, and the ceramic tile is fired.

6. The preparation method according to claim 5, characterized in that: The printing grayscale value of the hydrophobic mold ink is 10%-50%, and the printing volume is 10 g / m 2 -30 g / m 2 The amount of the hydrophilic mold glaze applied is 500 g / m 2 -600 g / m 2 .

7. The preparation method according to claim 5, characterized in that: The printing grayscale value of the glue ink is 10%-70%, and the printing volume is 50 g / m 2 -120 g / m 2 The amount of dry powder glaze applied is 100 g / m 2 -500 g / m 2 ; The specific gravity of the water-based protective glaze is 1.28 g / mL-1.32 g / mL, and the application amount is 150 g / m 2 -180 g / m 2 .

8. The preparation method according to claim 5, characterized in that: The sintering temperature is 1180°C-1190°C, and the sintering time is 45 min-60 min.

9. The preparation method according to claim 5, characterized in that: The moisture content of the green body layer is not more than 0.4% by mass, and its strength is 1.8 MPa-2.4 MPa.

10. The preparation method according to claim 5, characterized in that: After applying the dry powder glaze, the dry powder glaze not adhered by the glue ink is removed, and then the water-based protective glaze is sprayed.

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