A repair process for ceramic glaze defects

Abstract

The present invention discloses a repair process for ceramic glaze defects, comprising the following steps: A. grinding the defective part of the ceramic into a U-shaped groove, and wetting the U-shaped groove to obtain a pre-treated ceramic; B. filling the U-shaped groove of the pre-treated ceramic with a repair base material and compacting it to obtain a repair base layer; C. drying and grinding the repair base layer in sequence to make the surface of the repair base layer flush with the surface of the pre-treated ceramic; D. filling the repair glaze on the surface of the repair base layer and compacting it to form a repair surface layer; E. placing the pre-treated ceramic with the repair surface layer in a shuttle kiln to complete the repair. The present invention proposes a repair process for ceramic glaze defects, which is beneficial to reducing the firing shrinkage and the possibility of cracking and improving the repair strength by optimizing the formula of the repair base material and the repair process. On the premise of ensuring the repair effect, it can not only increase the range of repairable defects, but also make the repaired ceramic glaze defects smooth and flat, ensuring aesthetics.

Description

Technical Field

[0001] The invention relates to the technical field of ceramic sanitary ware, in particular to a repairing process for ceramic glaze defects. Background Art

[0002] Today, ceramic sanitary ware (such as sinks, bathtubs, and toilets) has become a fixture in countless households. With the continuous advancement of technology in the ceramic sanitary ware industry and the increasing demand for ceramic sanitary ware from consumers, ceramic sanitary ware has gradually become more complex in appearance and larger in size. Due to the complex appearance and large size of ceramic sanitary ware, the production process is complex and requires many steps. As a result, the glaze of the resulting ceramic sanitary ware is prone to various defects such as cracks and brown spots, which reduce the aesthetic appeal of the ceramic sanitary ware.

[0003] In order to solve the glaze defects of ceramic sanitary ware, it is generally necessary to use a repair process to repair the ceramic glaze defects to ensure that the performance of the ceramic sanitary ware is maintained, restore its beauty to the greatest extent, and enable the ceramic sanitary ware to continue to play its due value and role.

[0004] Existing repair processes primarily use a single layer of repair glaze as a repair material to repair defects and obtain a repair layer. However, this repair method is relatively rough, and the repair layer is easily worn away, resulting in poor repair results. To overcome these drawbacks, the industry has developed a method for repairing defects on ceramic glaze surfaces using a repair material consisting of a repair base material and a repair glaze. The repair base material is primarily composed of a mixture of raw materials such as bentonite, white pottery clay, and gypsum powder. However, the strength of the repair base material obtained by mixing these raw materials is relatively low, resulting in poor strength of the repaired defects and failing to meet high-quality repair requirements. Furthermore, if the calcination temperature of the repair base material is too high, the resulting repair base layer will be prone to bubbles and cracks, affecting the strength of the repaired surface. To lower the calcination temperature of the repair base material, a large amount of fluxing agents, such as potassium oxide and sodium oxide, are typically added to the repair base material. However, the addition of a large amount of flux results in a larger firing shrinkage rate for the repair base material, which also makes the resulting repair base layer prone to cracking and reduces the repair strength, further reducing the quality of the repair. In addition, due to the above-mentioned defects of the repair base material, the repair material can only repair defects with a length of less than 20 mm, a width of less than 1 mm and a depth of less than 1 mm, and the range of defects that can be repaired is very limited. Summary of the Invention

[0005] The purpose of the present invention is to propose a repair process for ceramic glaze defects. By optimizing the repair base material formula and the repair process, it is beneficial to reduce the firing shrinkage rate and the possibility of cracking and improve the repair strength. Under the premise of ensuring the repair effect, not only can defects with a length of ≤60mm, a width of ≤5mm and a depth of ≤5mm be repaired, thereby increasing the range of repairable defects, but also the repaired ceramic glaze defects can be made flat and smooth, and have no color difference from the rest of the ceramic glaze, ensuring aesthetics.

[0006] To achieve this object, the present invention adopts the following technical solutions:

[0007] A process for repairing ceramic glaze defects comprises the following steps:

[0008] A. Grinding the defects of the ceramic into a U-shaped groove and wetting the U-shaped groove to obtain the pretreated ceramic;

[0009] B. Filling the U-shaped groove of the pretreated ceramic with a repair base material and compacting it to obtain a repair base layer; wherein, calculated by weight, the repair base material comprises 30-40 parts of waste porcelain powder, 15-25 parts of pyrope powder, 25-35 parts of kyanite powder, 5-15 parts of fluxing block I, 2-10 parts of zirconium silicate, and 0.2-1 part of glass fiber, and the thermal expansion coefficient of the fluxing block I is (2-3)×10 -6 / ℃;

[0010] C. drying and polishing the repair base layer in sequence so that the surface of the repair base layer is flush with the surface of the pretreated ceramic;

[0011] D. filling the repair glaze on the surface of the repair base layer and compacting it to form a repair surface layer;

[0012] E. Place the pretreated ceramic with the repaired surface layer in a shuttle kiln, heat the shuttle kiln from room temperature to 1175-1185°C at a heating rate of 10-15°C / min and keep it warm for 23-25 ​​hours, then cool it down to room temperature at a cooling rate of 10-15°C / min to complete the repair.

[0013] Furthermore, in step B, the repair primer further comprises sodium carboxymethyl cellulose solution, glycerol and a preservative;

[0014] Calculated by mass, the repair base material includes 30-40 parts of waste porcelain powder, 15-25 parts of charcoal powder, 25-35 parts of kyanite powder, 5-15 parts of fluxing block I, 2-10 parts of zirconium silicate, 0.2-1 part of glass fiber, 2-6 parts of sodium carboxymethyl cellulose solution, 0.2-1 part of glycerol and 0.2-1 part of preservative.

[0015] Furthermore, in step D, the repair glaze comprises, calculated by weight, 85-95 parts of glaze slurry I, 10-15 parts of glaze slurry II, 2-10 parts of fluxing block II, and 0.2-0.5 parts of glycerol;

[0016] Calculated by weight, the top glaze slurry I includes 15-25 parts of feldspar, 20-30 parts of quartz, 3-5 parts of dolomite, 8-15 parts of wollastonite, 5-10 parts of calcium carbonate, 4-6 parts of kaolin, 3-5 parts of calcined alumina, 1-3 parts of calcined zinc oxide and 8-10 parts of zirconium silicate;

[0017] Calculated by weight, the top glaze slurry II includes 40 to 50 parts of feldspar, 15 to 25 parts of quartz, 20 to 30 parts of wollastonite and 10 to 20 parts of calcined zinc oxide.

[0018] Furthermore, the particle size of the fluxing block I and the fluxing block II are both ≤160 μm;

[0019] Calculated by mass percentage, the chemical compositions of the flux block I and the flux block II include SiO2 60-68%, Al2O3 6-14%, Fe2O3 0.10-0.50%, TiO2 0.01-0.05%, CaO 4-12%, MgO 0.15-0.5%, K2O 2-5%, Na2O 0.5-1.5%, ZrO2 0.10-0.50%, ZnO 0.20-0.60%, B2O3 8-12% and Ba0 0.30-0.60%, with the remainder being loss on ignition.

[0020] Furthermore, the diameter of the glass fiber is ≤30 mm.

[0021] Furthermore, in step B, the thickness of the repair bottom layer is 8 to 10 μm;

[0022] In step D, the thickness of the repair surface layer is 3 to 5 μm.

[0023] Furthermore, the particle size of the coke gemstone powder is ≤200 μm;

[0024] According to the mass percentage, the particle size of the kyanite powder is as follows: after passing through a 200-mesh sieve, the residue is 60-70%;

[0025] According to mass percentage, the particle size of the zirconium silicate is: after passing through a 325-mesh sieve, the residue is 0-0.5%.

[0026] Furthermore, the particle size of the waste porcelain powder is ≤200 μm;

[0027] Calculated by mass percentage, the chemical composition of the waste porcelain powder includes SiO2 65-73%, Al2O3 19-27%, Fe2O3 1-2%, TiO2 0.01-0.1%, CaO 0.5-1.5%, MgO 0.01-0.05%, K2O 2.5-3.5% and Na2O 0.5-1%, with the rest being loss on ignition.

[0028] Furthermore, the specific steps in step A are: first use a carbon rod vibrating pen to grind the defects of the ceramic into a U-shaped groove, blow away the polished ceramic powder with an air gun, and then wipe and moisten the U-shaped groove with a wet towel to obtain pretreated ceramic.

[0029] Furthermore, in step B, the preparation method of the repair base material is as follows: after uniformly mixing the formulated amount of waste porcelain powder, coke sapphire powder, kyanite powder, flux block I and zirconium silicate, an intermediate slurry I is obtained; and then, after uniformly mixing the formulated amount of glass fiber, sodium carboxymethyl cellulose, glycerol and preservative, the intermediate slurry I is added, and the repair base material is obtained.

[0030] In step D, the preparation method of the repair glaze is: after uniformly mixing the formulated amount of glaze slurry I, glaze slurry II and fluxing block II, an intermediate slurry II is obtained; and after uniformly mixing the formulated amount of propylene glycol into the intermediate slurry II, a repair glaze is obtained.

[0031] The technical solutions provided by the embodiments of the present application may have the following beneficial effects:

[0032] 1. Before filling the repair glaze, first fill the repair base material into the U-shaped groove of the pretreated ceramic and compact it to ensure that the repair base material fully fills the U-shaped groove. On the one hand, it reduces the gap between the repair base material and the pretreated ceramic body to ensure the close combination of the two. On the other hand, it helps to avoid the presence of bubbles or gaps in the repair base material after filling, which causes cracks after calcination and affects the repair effect. In addition, the repair base material provided by this solution has high strength, and the volume shrinkage rate of the repair base material after calcination is small and the possibility of cracking is extremely low. It is not only beneficial to improve the repair effect, but also can repair defects with a length of ≤60mm, a width of ≤5mm and a depth of ≤5mm, thereby increasing the range of repairable defects.

[0033] 2. Use a shuttle kiln for calcination. Specifically, the shuttle kiln is heated from room temperature to 1175-1185°C at a heating rate of 10-15°C / min and kept at this temperature for 23-25 ​​hours. Then, the temperature is cooled to room temperature at a cooling rate of 10-15°C / min to obtain a ceramic with a repair layer, completing the repair. The use of low calcination temperature, long calcination time, low heating rate and low cooling rate can effectively alleviate the impact of thermal stress on the repair material, reduce the wear and cracking of the repair layer, and make the refired ceramic sanitary ware smooth and flat after repair, and have no obvious color difference from the original product. At the same time, compared with the simple structure of the tunnel kiln, the shuttle kiln is more complex, with many channels and layers inside. When the pre-treated ceramic with the repair surface layer enters the kiln, it needs to go through a series of stops, rests, and heating processes before calcination is completed. This is more conducive to alleviating the impact of thermal stress on the repair material and ensuring the repair effect. DETAILED DESCRIPTION

[0034] This technical solution provides a process for repairing ceramic glaze defects, comprising the following steps:

[0035] A. Grinding the defects of the ceramic into a U-shaped groove and wetting the U-shaped groove to obtain the pretreated ceramic;

[0036] B. Filling the U-shaped groove of the pretreated ceramic with a repair base material and compacting it to obtain a repair base layer; wherein, calculated by weight, the repair base material comprises 30-40 parts of waste porcelain powder, 15-25 parts of pyrope powder, 25-35 parts of kyanite powder, 5-15 parts of fluxing block I, 2-10 parts of zirconium silicate, and 0.2-1 part of glass fiber, and the thermal expansion coefficient of the fluxing block I is (2-3)×10 -6 / ℃;

[0037] C. drying and polishing the repair base layer in sequence so that the surface of the repair base layer is flush with the surface of the pretreated ceramic;

[0038] D. filling the repair glaze on the surface of the repair base layer and compacting it to form a repair surface layer;

[0039] E. Place the pretreated ceramic with the repaired surface layer in a shuttle kiln, heat the shuttle kiln from room temperature to 1175-1185°C at a heating rate of 10-15°C / min and keep it warm for 23-25 ​​hours, then cool it down to room temperature at a cooling rate of 10-15°C / min to complete the repair.

[0040] In order to solve the defects of poor repair effect and limited repair range in the existing technology, the present technical solution proposes a repair process for ceramic glaze defects, including five steps: A (pretreatment), B (filling repair base material), C (polishing), D (filling repair glaze) and E (calcining in the kiln). Then, through the innovative repair base material formula combined with the repair process, the ceramic defects are repaired. The whole repair process is simple and easy to operate, which is conducive to reducing the firing shrinkage rate and the possibility of cracking and improving the repair strength. On the premise of ensuring the repair effect, not only can defects with a length of ≤60mm, a width of ≤5mm and a depth of ≤5mm be repaired, thereby increasing the range of repairable defects, but also the repaired ceramic glaze defects can be made flat and smooth, and have no color difference with the rest of the ceramic glaze, ensuring the aesthetics after repair.

[0041] Specifically, because cracks or pores in ceramic glaze defects are generally small, directly filling them with a repair primer will result in poor filling and difficulty ensuring a successful repair. Therefore, this technical solution first grinds the ceramic defect into a U-shaped groove, facilitating subsequent repair and filling. After grinding, the U-shaped groove is moistened to ensure effective adhesion of the repair primer, ensuring a successful repair.

[0042] Secondly, before filling the repair glaze, this technical solution first fills the repair base material into the U-shaped groove of the pretreated ceramic and compacts it to ensure that the repair base material fully fills the U-shaped groove. On the one hand, it reduces the gap between the repair base material and the pretreated ceramic body to ensure a close combination of the two. On the other hand, it helps to avoid the presence of bubbles or gaps in the repair base material after filling, which causes cracks after calcination and affects the repair effect. In addition, the repair base material provided by this solution has high strength, and the volume shrinkage rate of the repair base material after calcination is small and the possibility of cracking is extremely low. It is not only beneficial to improve the repair effect, but also can repair defects with a length of ≤60mm, a width of ≤5mm and a depth of ≤5mm, thereby increasing the range of repairable defects.

[0043] Furthermore, the repair base material is mainly made of a mixture of raw materials such as bentonite, white pottery mud and gypsum powder, but the strength of the above raw materials is relatively low, which makes the strength of the mixed repair base material relatively low, and the strength of the defect after repair is relatively poor, which cannot meet the high-quality repair requirements. The repair base material of this technical solution includes waste porcelain powder, kyanite powder, pyrotechnics powder, fluxing block, zirconium silicate and glass fiber. Among them, waste porcelain powder is a powder formed by grinding ceramic waste, so it has high strength itself, thus giving the repair base material high strength; glass fiber is a fibrous material formed by a fiberization process after high-temperature melting of glass raw materials. It has extremely high strength and can also significantly improve the strength of the repair base material; pyrotechnics powder is a powder obtained by grinding, drying, crushing and screening pyrotechnics. Its main components are high-strength aluminum oxide and silicon dioxide, which also give the repair base material high strength; zirconium silicate added to the repair base material formula is also beneficial to improving the strength of the repair base material. Therefore, the combination of waste porcelain powder, glass fiber, pyrotechnic jewel powder, and zirconium silicate in the repair base material formula of this technical solution ensures high strength, and the resulting calcined repair base layer also has high strength, meeting the requirements of high-quality repairs. Furthermore, zirconium silicate helps improve the whiteness of the repair base material, preventing the base layer from being too dark and affecting the overall decorative effect of the repaired ceramic sanitary ware.

[0044] Furthermore, the shape of glass fiber is generally continuous fiber, and its unique fiber structure can form a stable skeleton structure in the material, which not only enables it to effectively resist the volume shrinkage of the flux components in the repair base material after high-temperature calcination, but also provides skeleton support for the repair base material, avoiding high-temperature calcination cracks in the repair base material.

[0045] Kyanite powder will expand in volume during high-temperature calcination. Its expansion under high-temperature conditions can not only effectively offset the loose stacking produced during the filling process of the repair base material, but also offset the volume shrinkage of the flux components in the repair base material after high-temperature calcination, thereby eliminating the repair cracks caused by stress and reducing the possibility of crack expansion, greatly improving the repair range of the repair base material.

[0046] Pyrope powder can penetrate the pores and cracks of the repair base material, effectively filling these spaces and improving the density and overall performance of the repair base material. Pyrope powder also has a certain volume stability at high temperatures. When the repair base material is fired at high temperatures, the pyrope powder can effectively reduce the volume shrinkage of the repair base material after calcination.

[0047] Waste porcelain powder can enter the pores and cracks of the repair base material, effectively filling these spaces and improving the density and overall performance of the repair base. Furthermore, because waste porcelain powder is a clinker calcined at high temperatures, it has high volume stability and forms a stable bond between particles. This helps reduce stress concentration and crack propagation caused by shrinkage during the repair base material calcination process, thereby improving the overall stability of the repair base material. Furthermore, as a skeleton material, waste porcelain powder maintains the same key properties as the pretreated ceramic body, facilitating a tight bond between the two and preventing peeling.

[0048] At the same time, the repair base material formula also includes flux block I, which can reduce the sintering temperature of the repair base material, so that the repair base material can be calcined at a lower temperature to form a eutectic glass body, achieve a vitrification effect and closely combine with the pretreated ceramic body, thereby improving the bonding firmness; at the same time, the thermal expansion coefficient of flux block I in this technical solution is (2-3)×10 -6 / °C. Compared with existing fluxes such as potassium oxide and sodium oxide, its expansion coefficient is extremely low, significantly reducing the volume shrinkage of the repair base material after calcination. This not only reduces the possibility of cracking after calcination, but also helps to increase the range of repairable defects. Furthermore, in this technical solution, the addition amount of flux block I is limited to 5-15 parts. This allows the repair base material to be fully calcined and vitrified at a relatively low addition amount, ensuring a strong bond with the pretreated ceramic body while also helping to reduce volume shrinkage after calcination.

[0049] If the calcining temperature of the repair base material is too high, the repair bottom obtained by calcining will be prone to bubbles and cracking, affecting the strength after repair. In order to reduce the calcining temperature of the repair base material, a large amount of fluxes are usually added in the repair base material, such as potassium oxide and sodium oxide, but the addition of a large amount of fluxes causes the sintering shrinkage of the repair base material to be larger, which also makes the repair bottom obtained by calcining easily crack, and the repair strength will also be reduced, further reducing its repair quality. Therefore, in the present technical solution, by the mutual coordination of glass fiber, kyanite powder, waste porcelain powder, coke stone powder and fluxing block, and limiting the thermal expansion coefficient and addition of fluxing block 1, the volume shrinkage and cracking possibility of the repair base material after calcining are greatly reduced, which is not only conducive to improving the repair effect, but also can repair the defects of length≤60mm, width≤5mm and depth≤5mm, improve the repairable defect range, solve the problem that the volume shrinkage of the repair base material after calcining in the prior art is too large, easily cracks, causes the repair strength to deteriorate, and repairs the technical defects of limited defect range.

[0050] Furthermore, the main components of pyro-gem powder are alumina and silica, which possess high hardness and chemical stability. This gives the pyro-gem powder chemical stability and high wear resistance, which helps extend the service life of the repair layer. Furthermore, the high-temperature calcination process of pyro-gem powder also produces mullite, which helps improve the thermal shock resistance of the repair base material.

[0051] Before filling the repair glaze, the present technical solution also needs to dry and polish the repair base layer in sequence to make the surface of the pretreated ceramics flush. The drying step is conducive to the preliminary solidification of the repair base layer, which prevents it from being easily polished away during the subsequent polishing process, increasing the difficulty of polishing. At the same time, through the polishing step, on the one hand, the burrs, oil stains, dust and other impurities on the surface of the repair base layer can be removed, so that the repair surface layer formed by the repair glaze can be better combined with the repair base layer. On the other hand, polishing makes the surface of the repair base layer flush with the surface of the pretreated ceramics, which can reduce the obviousness of the repair marks. The repaired ceramic sanitary ware is visually closer to the original state, which improves the concealment and aesthetics of the repair. In addition, since the surface of the repair base layer is smooth and free of impurities after polishing, the application of the repair glaze is smoother, reducing the problem of repair difficulties and reduced efficiency due to the uneven surface of the repair base layer or the presence of impurities.

[0052] Next, the repair glaze is filled on the surface of the repair base and compacted to form a repair surface layer. The repair glaze can restore the original color and texture of the ceramic sanitary ware, making the defects of the repaired ceramic glaze visually consistent with the rest of the surface, making it difficult to detect the repair traces. At the same time, after filling and compacting, the repair glaze has a smooth and flat surface, which perfectly blends with the rest of the ceramic glaze surface, improving the overall aesthetics. In addition, the repair glaze can protect the repair base from erosion by the external environment and form a solid protective layer, improving the durability of the repaired ceramic.

[0053] Finally, the prior art generally uses tunnel kilns for calcination. However, tunnel kilns have high calcination temperatures, short calcination times, and rapid heating rates, resulting in large thermal stresses during the calcination process. This easily causes cracks in the calcined ceramic sanitary ware, making it difficult to guarantee the repair effect even with a repair base material with low shrinkage and low cracking potential. Therefore, the present technical solution uses a shuttle kiln for calcination. Specifically, the shuttle kiln is heated from room temperature to 1175-1185°C at a heating rate of 10-15°C / min and held at this temperature for 23-25 ​​hours. The temperature is then cooled to room temperature at a cooling rate of 10-15°C / min to obtain a ceramic with a repair layer, completing the repair. The use of low calcination temperatures, long calcination times, and slow heating and cooling rates effectively alleviates the effects of thermal stress on the repair material, reduces wear and cracking of the repair layer, and ensures that the repaired defects of the refired ceramic sanitary ware are smooth and flat, with no significant color difference from the original product. At the same time, compared with the simple structure of the tunnel kiln, the shuttle chamber kiln has a more complex structure with many channels and layers inside. When the pretreated ceramics with a repair surface layer enter the kiln, they need to go through a series of stops, rests and heating processes before calcination can be completed, which is more conducive to alleviating the impact of thermal stress on the repair material and ensuring the repair effect.

[0054] Therefore, this technical solution uses an innovative repair base material formula to replace the existing technology that uses a mixture of bentonite, white pottery mud and gypsum powder to repair defects on ceramic glaze surfaces. Combined with the repair process, the repair base material has the characteristics of high strength, low volume shrinkage and low cracking possibility, and the shuttle kiln calcination process is not prone to cracks. Under the premise of ensuring the repair effect, it can not only repair defects with a length of ≤60mm, a width of ≤5mm and a depth of ≤5mm, thereby increasing the range of repairable defects, but also make the repaired ceramic glaze defects smooth and flat, and have no color difference with the rest of the ceramic glaze, ensuring aesthetics.

[0055] In addition, the repair process of this scheme is efficient and simple, with low repair difficulty and high production efficiency. The color of the obtained repair layer is close to the ceramic glaze surface, and can be widely used in repairing ceramic glaze defects.

[0056] Further, in step B, the repair primer further includes sodium carboxymethyl cellulose solution, glycerol and a preservative;

[0057] Calculated by mass, the repair base material includes 30-40 parts of waste porcelain powder, 15-25 parts of charcoal powder, 25-35 parts of kyanite powder, 5-15 parts of fluxing block I, 2-10 parts of zirconium silicate, 0.2-1 part of glass fiber, 2-6 parts of sodium carboxymethyl cellulose solution, 0.2-1 part of glycerol and 0.2-1 part of preservative.

[0058] In a preferred embodiment of the present technical solution, the repair base also includes sodium carboxymethyl cellulose solution, glycerol and a preservative, wherein the sodium carboxymethyl cellulose solution can increase the adhesion of the repair base, reduce the drying shrinkage of the repair base, prevent defects such as glaze rolling and glaze chipping, thereby improving the filling effect and helping to increase the range of defects that can be repaired; glycerol can ensure the moisture retention of the repair base, prevent the repair base from drying quickly and causing fine lines or cracks, and improve the plasticity and ductility of the repair base; the preservative can prevent the repair base from being invaded by microorganisms and molds during processing and use, thereby extending the quality and service life of the repair base. Therefore, in the present technical solution, by adding sodium carboxymethyl cellulose solution, glycerol and a preservative to the repair base formula, it is not only beneficial to extend the quality and service life of the repair base, but also to avoid cracks in the drying process of the repair base, ensuring its filling effect and increasing the range of defects that can be repaired.

[0059] Furthermore, calculated by mass, the repair base material includes 30-40 parts of waste porcelain powder, 15-25 parts of charcoal gemstone, 25-35 parts of kyanite, 5-15 parts of flux block I, 2-10 parts of zirconium silicate, 0.2-1 part of glass fiber, 2-6 parts of sodium carboxymethyl cellulose solution, 0.2-1 part of propylene glycol and 0.2-1 part of preservative. By adjusting the amount of each raw material added in the repair base material formula, it is beneficial to achieve better performance of the repair base material and ensure the repair effect.

[0060] Preferably, the preservative includes at least one of benzoic acid, sodium benzoate, sorbic acid, and potassium sorbate. Benzoic acid, sodium benzoate, sorbic acid, and potassium sorbate all have excellent preservative effects. Adding them to the formula helps prevent the repair base from being attacked by microorganisms and mold during processing and use, thereby extending the quality and service life of the repair base.

[0061] Preferably, calculated by mass percentage, the sodium carboxymethyl cellulose solution comprises 95-97% sodium carboxymethyl cellulose and 3-5% water.

[0062] Further, in step D, the repair glaze includes 85-95 parts of glaze slurry I, 10-15 parts of glaze slurry II, 2-10 parts of flux block II and 0.2-0.5 parts of glycerol, calculated by weight;

[0063] Calculated by weight, the top glaze slurry I includes 15-25 parts of feldspar, 20-30 parts of quartz, 3-5 parts of dolomite, 8-15 parts of wollastonite, 5-10 parts of calcium carbonate, 4-6 parts of kaolin, 3-5 parts of calcined alumina, 1-3 parts of calcined zinc oxide and 8-10 parts of zirconium silicate;

[0064] Calculated by weight, the top glaze slurry II includes 40 to 50 parts of feldspar, 15 to 25 parts of quartz, 20 to 30 parts of wollastonite and 10 to 20 parts of calcined zinc oxide.

[0065] In a preferred embodiment of this technical solution, the raw materials for the repair glaze include glaze slurry I, glaze slurry II, fluxing block II, and glycerol. Glaze slurry I is used to improve the hardness, strength, wear resistance, and corrosion resistance of the repair glaze, while glaze slurry II is used to enhance the whiteness and gloss of the repair glaze. The interaction between glaze slurry I and glaze slurry II ensures the performance of the repair glaze.

[0066] In addition, the raw materials of the repair glaze also include flux block II and propylene glycol. Flux block II is an important additive in the repair glaze, which can reduce the melting temperature of the repair glaze, making the repair glaze easier to combine with the repair base material and the pretreated ceramic body; propylene glycol mainly plays the role of wetting and adjusting the viscosity of the glaze slurry, which can make the repair glaze slurry easier to apply and evenly distribute, and help the repair glaze to form a uniform repair surface layer after calcination, thereby ensuring the repair effect.

[0067] Furthermore, calculated by mass, the repair glaze includes 85-95 parts of glaze slurry I, 10-15 parts of glaze slurry II, 2-10 parts of flux block II and 0.2-0.5 parts of propylene glycol. By adjusting the amount of each raw material added in the repair glaze formula, it is beneficial to achieve better performance of the repair base material and ensure the repair effect.

[0068] It is further stated that the particle size of the fluxing block I and the fluxing block II are both ≤160 μm;

[0069] Calculated by mass percentage, the chemical compositions of the flux block I and the flux block II include SiO2 60-68%, Al2O3 6-14%, Fe2O3 0.10-0.50%, TiO2 0.01-0.05%, CaO 4-12%, MgO 0.15-0.5%, K2O 2-5%, Na2O 0.5-1.5%, ZrO2 0.10-0.50%, ZnO 0.20-0.60%, B2O3 8-12% and Ba0 0.30-0.60%, with the remainder being loss on ignition.

[0070] If the particle size of flux block I and flux block II is too large, it will lead to an increase in glass phase, uneven local stress during calcination, and affect the repair effect; if the particle size of flux block I and flux block II is too small, it will increase the difficulty of their processing and production, reduce production efficiency, and thus increase production costs. Therefore, in a preferred embodiment of the present technical solution, the particle size of flux block I and flux block II is limited to less than 160μm, which is beneficial to ensure their fluxing effect and repair effect at a lower production cost.

[0071] Furthermore, the chemical composition of flux block I and flux block II includes SiO2, Al2O3, Fe2O3, TiO2, CaO, MgO, K2O, Na2O, ZrO2, ZnO, B2O3 and Ba0, among which K2O and Na2O can broaden the firing range, have good stability, and reduce the melting temperature and high-temperature viscosity; B2O3 can play a role in fluxing, reduce the thermal expansion coefficient, and improve the thermal shock resistance, which is conducive to matching the performance of the pretreated ceramic itself and avoiding bumps during calcination; in addition, B203 can also reduce the amount of K2O and Na2O added, ensuring a better fluxing effect while also having an extremely low thermal expansion coefficient; CaO can reduce the viscosity during high-temperature melting, enhance the bonding strength of the body and glaze, and prevent the occurrence of glaze baldness; SiO2 can increase high-temperature viscosity, strength and calcination temperature; Al2O3 can increase high-temperature viscosity, initial melting point, hardness, acid and alkali resistance and chemical stability; MgO can increase the melting temperature range at high temperatures; K2O and Na2O can widen the firing range, have better stability, and reduce the melting temperature and high-temperature viscosity.

[0072] Therefore, in this technical solution, the chemical composition of flux block I and flux block II is optimized, and the addition amount of each chemical component is limited to ensure that flux block I and flux block II not only have a good fluxing effect, but also have an extremely low thermal expansion coefficient; in addition, flux block I and flux block II are also beneficial to improve the thermal shock resistance, which is beneficial to matching the performance of the pretreated ceramic itself, avoiding bumps during calcination, and ensuring the repair effect.

[0073] It is further specified that the diameter of the glass fiber is ≤30 mm.

[0074] In a preferred embodiment of the present technical solution, the diameter of the glass fiber is limited to within 30 mm, so that it can not only increase the mechanical strength and tensile properties of the repair base material, but also fill the calcination cracks that appear during the calcination process of the repair base material, reduce the possibility of cracking of the repair base layer, and ensure the repair effect.

[0075] Further, in step B, the thickness of the repair bottom layer is 8 to 10 μm;

[0076] In step D, the thickness of the repair surface layer is 3 to 5 μm.

[0077] The thickness of the repair base layer is 8-10 μm. If the thickness of the repair base layer is too thick, it will increase the difficulty of grinding and reduce the repair efficiency. If the thickness of the repair base layer is too thin, the strength and hardness of the repaired material will be insufficient, affecting its service life. Therefore, in a preferred embodiment of this technical solution, the thickness of the repair base layer is limited to 8-10 μm, which is conducive to improving repair efficiency and extending service life.

[0078] Furthermore, if the thickness of the repair surface layer is too thick, it will easily increase the repair cost and easily cause a height difference between the repaired ceramic glaze defect and the surrounding area, affecting the repair effect. If the thickness of the repair surface layer is too thin, it will reduce the protection of the repair base layer and easily wear it, also affecting the repair effect. Therefore, in a preferred embodiment of this technical solution, the thickness of the repair surface layer is limited to 3-5μm to ensure the repair effect.

[0079] It is further stated that the particle size of the coke gemstone powder is ≤200 μm;

[0080] According to the mass percentage, the particle size of the kyanite powder is as follows: after passing through a 200-mesh sieve, the residue is 60-70%;

[0081] According to mass percentage, the particle size of the zirconium silicate is: after passing through a 325-mesh sieve, the residue is 0-0.5%.

[0082] If the particle size of the coke gem powder is too large, the mullite crystal phase produced by the coke gem powder during the high-temperature calcination process will increase locally, causing uneven shrinkage of the repair base material.

[0083] If the particle size of kyanite powder is too large, the water absorption rate of the repair base material will increase and the flexural strength will decrease; if the particle size of kyanite powder is too small, it will easily lose its high-temperature expansion properties, making the repair base material prone to cracking during calcination.

[0084] If the particle size of zirconium silicate is too small, its hardness and strength will be reduced, thereby affecting the relevant properties of the repair base material; if the particle size of zirconium silicate is too large, the porosity of the repair base material will increase, making it more likely to crack.

[0085] Therefore, in a preferred embodiment of the technical solution, the particle sizes of the sapphire powder, kyanite powder and zirconium silicate are limited to ensure the performance of the repair base material and improve the repair effect.

[0086] It is further stated that the particle size of the waste porcelain powder is ≤200 μm;

[0087] Calculated by mass percentage, the chemical composition of the waste porcelain powder includes SiO2 65-73%, Al2O3 19-27%, Fe2O3 1-2%, TiO2 0.01-0.1%, CaO 0.5-1.5%, MgO 0.01-0.05%, K2O 2.5-3.5% and Na2O 0.5-1%, with the rest being loss on ignition.

[0088] In a preferred embodiment of the present technical solution, by optimizing the particle size and composition of the waste porcelain powder, it is ensured that the waste porcelain powder can not only fully fill the gaps in the repair base material and reduce its volume shrinkage during the calcination process, but also help to improve the hardness and strength of the repair base material.

[0089] To further illustrate, the specific steps in step A are: first use a carbon rod vibrating pen to grind the defects of the ceramic into a U-shaped groove, blow away the polished ceramic powder with an air gun, and then wipe and moisten the U-shaped groove with a wet towel to obtain pretreated ceramic.

[0090] Since the carbon rod has high hardness, the hardness and vibration of the carbon rod are used to polish and shape the ceramic surface, so that the defects of the ceramic are polished into a regular U-shaped groove, which is helpful for subsequent repair and filling work. The ceramic powder is blown away by an air gun that can generate high-speed airflow to ensure the smooth progress of the subsequent steps. In addition, there may still be tiny powder particles or stains remaining on the surface of the U-shaped groove after polishing. In order to obtain a clean and smooth repair surface, wipe it with a wet towel to absorb and remove the tiny particles or stains on the surface, ensuring that the surface of the U-shaped groove is cleaner and smoother. At the same time, the wet towel can also moisten the U-shaped groove, which is beneficial for subsequent filling and repair work, ensuring that the repaired ceramic has better appearance and performance.

[0091] Further, in step B, the preparation method of the repair base material is as follows: after uniformly mixing the formulated amount of waste porcelain powder, coke sapphire powder, kyanite powder, flux block I and zirconium silicate, an intermediate slurry I is obtained; and then, the formulated amount of glass fiber, sodium carboxymethyl cellulose, glycerol and preservative are added to the intermediate slurry I, and the mixture is uniformly stirred to obtain the repair base material;

[0092] In step D, the preparation method of the repair glaze is: after uniformly mixing the formulated amount of glaze slurry I, glaze slurry II and fluxing block II, an intermediate slurry II is obtained; and after uniformly mixing the formulated amount of propylene glycol into the intermediate slurry II, a repair glaze is obtained.

[0093] In a preferred embodiment of the present technical solution, an intermediate slurry I is obtained by uniformly mixing the formulated amounts of waste porcelain powder, coke sapphire powder, kyanite powder, fluxing block I and zirconium silicate; then the formulated amounts of glass fiber, sodium carboxymethyl cellulose, propylene glycol and preservative are added to the intermediate slurry I, and stirred evenly to obtain a repair base material; the formulated amounts of glaze slurry I, glaze slurry II and fluxing block are mixed evenly to obtain an intermediate slurry II; then the formulated amount of propylene glycol is added to the intermediate slurry II and mixed evenly to obtain a repair glaze. The preparation method is simple and easy to operate, ensuring that the obtained repair base material has high strength, and its calcination shrinkage and cracking possibility are extremely low, and the obtained repair glaze has strong wear resistance, corrosion resistance, whiteness and glossiness. On the premise of ensuring the repair effect, it not only increases the range of repairable defects, but also makes the defects on the repaired ceramic glaze surface smooth and has no color difference with the rest of the ceramic glaze surface, ensuring aesthetics. It should be noted that the intermediate slurry II is obtained by first mixing the formulated amount of glaze slurry I, glaze slurry II, glaze slurry and flux block II evenly, which can ensure that the glaze slurry I, glaze slurry II and flux block II are fully integrated to form a stable intermediate slurry II; and the glaze slurry I, glaze slurry II and flux block II are added after they are evenly mixed to ensure that propylene glycol is evenly distributed in the repair glaze, thereby giving full play to its moisturizing properties, ductility and crack resistance.

[0094] The technical solution of the present invention is further illustrated below through specific implementation methods.

[0095] Performance testing:

[0096] Repair effect: Observe the repair effect of the ceramic glaze defects with the naked eye;

[0097] Thermal shock resistance: Place the repaired ceramic sanitary ware in a furnace preheated to 110°C, keep warm for 20 minutes, then quench in room temperature water for 3 minutes. After drying, observe whether there are cracks in the repair layer.

[0098] Firing shrinkage rate: Place the repair layer in a beaker and add 100℃ boiling water to soak for 15 minutes. Take out the repair layer and wait until it is completely dry. Use a caliper or ruler to measure the length of the repair layer before and after water immersion. Divide the difference in length of the repair layer before and after water immersion by the length before water immersion, and multiply the difference by 100% to obtain the percentage of boiling water shrinkage rate.

[0099] Example Group

[0100] Example 1

[0101] A. First, a carbon rod vibrating pen was used to grind a U-shaped groove with a length of 55 mm, a width of 4 mm, and a depth of 4.5 mm on the ceramic. After blowing away the polished ceramic powder with an air gun, the U-shaped groove was wiped and moistened with a wet towel to obtain the pretreated ceramic.

[0102] B. Fill the U-shaped groove of the pretreated ceramic with a repair base material and compact it to obtain a repair base layer. The repair base material, calculated by mass, includes 30 parts of waste porcelain powder, 25 parts of pyrope stone powder, 25 parts of kyanite powder, 10 parts of fluxing block I, 10 parts of zirconium silicate, 0.8 parts of glass fiber, 4 parts of sodium carboxymethyl cellulose solution, 0.2 parts of glycerol, and 0.2 parts of sodium benzoate. The thickness of the repair base layer is 10 μm. The particle size of fluxing block I is 150 μm, and the thermal expansion coefficient of fluxing block I is 2.2×10 -6 / ℃, calculated by mass percentage, the chemical composition of flux block I includes SiO2 65%, Al2O3 6%, Fe2O3 0.50%, TiO2 0.01%, CaO 12%, MgO 0.5%, K2O 3%, Na2O 1.0%, ZrO2 0.10%, ZnO 0.40%, B2O3 10% and Ba00.30%, with the remainder being loss on ignition; the diameter of the glass fiber is 25 mm; the particle size of the pyrope powder is 200 μm; the particle size of the kyanite powder is: 60-70% on a 200-mesh sieve; the particle size of the zirconium silicate is: 0-0.5% on a 325-mesh sieve; the particle size of the waste porcelain powder is 180 μm; the chemical composition of the waste porcelain powder is: SiO2 68%, Al2O3 20%, Fe2O32%, TiO2 0.1%, CaO 1.5%, MgO 0.05%, K2O3.5% and Na2O 1%, the rest is loss on ignition;

[0103] C. Dry and polish the repair base layer in sequence to make the surface of the repair base layer flush with the surface of the pretreated ceramic;

[0104] D. Fill the repair glaze on the surface of the repair base and compact it to form a repair surface layer; the thickness of the repair surface layer is 3-5 μm; calculated by weight, the repair glaze includes 85 parts of glaze slurry I, 15 parts of glaze slurry II, 3 parts of fluxing block II and 0.2 parts of propylene glycol; calculated by weight, the glaze slurry I includes 15 parts of feldspar, 30 parts of quartz, 5 parts of dolomite, 10 parts of wollastonite, 10 parts of calcium carbonate, 4 parts of kaolin, 3 parts of calcined alumina, 2 parts of calcined zinc oxide and 8 parts of zirconium silicate; calculated by weight, the glaze slurry II includes 40 parts of feldspar, 25 parts of quartz, 30 parts of wollastonite and 20 parts of calcined zinc oxide; the particle size of fluxing block II is 150 μm, and the thermal expansion coefficient of fluxing block II is 2.2×10 -6 / ℃, calculated by mass percentage, the chemical composition of flux block II includes SiO2 65%, Al2O3 6%, Fe2O3 0.50%, TiO2 0.01%, CaO 12%, MgO 0.5%, K2O3%, Na2O 1.0%, ZrO2 0.10%, ZnO 0.40%, B2O3 10% and Ba0 0.30%, and the rest is loss on ignition; the diameter of the glass fiber is 25mm;

[0105] E. Place the pretreated ceramic with the repaired surface layer in a shuttle kiln, heat the shuttle kiln from room temperature to 1175-1185°C at a heating rate of 10-15°C / min and keep it warm for 23-25 ​​hours, then cool it down to room temperature at a cooling rate of 10-15°C / min to complete the repair.

[0106] Example 2

[0107] A. First, a carbon rod vibrating pen was used to grind a U-shaped groove with a length of 60 mm, a width of 5 mm, and a depth of 5 mm on the ceramic. After blowing away the polished ceramic powder with an air gun, the U-shaped groove was wiped and moistened with a wet towel to obtain the pretreated ceramic.

[0108] B. Fill the U-shaped groove of the pretreated ceramic with a repair base material and compact it to obtain a repair base layer. The repair base material, calculated by mass, includes 35 parts of waste porcelain powder, 15 parts of pyrope stone powder, 35 parts of kyanite powder, 15 parts of fluxing block I, 2 parts of zirconium silicate, 1 part of glass fiber, 2 parts of sodium carboxymethyl cellulose solution, 0.2 parts of glycerol, and 0.8 parts of benzoic acid. The thickness of the repair base layer is 10 μm. The particle size of fluxing block I is 140 μm, and the thermal expansion coefficient of fluxing block I is 2×10 -6 / ℃, calculated by mass percentage, the chemical composition of flux block I includes SiO2 68%, Al2O3 14%, Fe2O3 0.10%, TiO2 0.05%, CaO 8%, MgO0.15%, K2O 5%, Na2O 1.0%, ZrO2 0.50%, ZnO 0.40%, B2O3 10% and Ba0 0.5%, with the remainder being loss on ignition; the diameter of the glass fiber is 25 mm; the particle size of the pyrope stone powder is 170 μm; the particle size of the kyanite powder is: 60-70% on a 200-mesh sieve; the particle size of the zirconium silicate is: 0-0.5% on a 325-mesh sieve; the particle size of the waste porcelain powder is 180 μm; the chemical composition of the waste porcelain powder is: SiO2 73%, Al2O3 19%, Fe2O3 2%, TiO2 0.1%, CaO 0.5%, MgO 0.03%, K2O 3% and Na2O 1%, the rest is loss on ignition;

[0109] C. Dry and polish the repair base layer in sequence to make the surface of the repair base layer flush with the surface of the pretreated ceramic;

[0110] D. Fill the repair glaze on the surface of the repair base and compact it to form a repair surface layer; the thickness of the repair surface layer is 3 μm; calculated by weight, the repair glaze includes 95 parts of glaze slurry I, 12 parts of glaze slurry II, 4 parts of fluxing block II and 0.4 parts of propylene glycol; calculated by weight, the raw materials of glaze slurry I include 20 parts of feldspar, 30 parts of quartz, 4 parts of dolomite, 10 parts of wollastonite, 8 parts of calcium carbonate, 4 parts of kaolin, 5 parts of calcined alumina, 3 parts of calcined zinc oxide and 10 parts of zirconium silicate; calculated by weight, the glaze slurry II includes 50 parts of feldspar, 15 parts of quartz, 25 parts of wollastonite and 15 parts of calcined zinc oxide; the particle size of fluxing block II is 140 μm, and the thermal expansion coefficient of fluxing block II is 2×10 -6 / ℃, calculated by mass percentage, the chemical composition of flux block II includes SiO2 68%, Al2O3 14%, Fe2O3 0.10%, TiO2 0.05%, CaO 8%, MgO 0.15%, K2O5%, Na2O 1.0%, ZrO2 0.50%, ZnO 0.40%, B203 10% and Ba0 0.5%, and the rest is loss on ignition;

[0111] E. Place the pretreated ceramic with the repaired surface layer in a shuttle kiln, heat the shuttle kiln from room temperature to 1175-1185°C at a heating rate of 15°C / min and keep it warm for 25 hours, then cool it down to room temperature at a cooling rate of 10°C / min to complete the repair.

[0112] Example 3

[0113] A. First, use a carbon rod vibrating pen to grind a U-shaped groove on the ceramic with a length of 50 mm, a width of 5 mm, and a depth of 4 mm. After blowing away the polished ceramic powder with an air gun, wipe and wet the U-shaped groove with a wet towel to obtain pretreated ceramic.

[0114] B. Fill the U-shaped groove of the pretreated ceramic with a repair base material and compact it to obtain a repair base layer. The repair base material, calculated by mass, includes 40 parts of waste porcelain powder, 18.2 parts of pyrope stone powder, 30 parts of kyanite powder, 5 parts of fluxing block I, 5 parts of zirconium silicate, 0.2 parts of glass fiber, 6 parts of sodium carboxymethyl cellulose solution, 0.6 parts of glycerol, and 1 part of sorbic acid. The thickness of the repair base layer is 9 μm. The particle size of fluxing block I is 130 μm, and the thermal expansion coefficient of fluxing block I is 2.5×10 -6 / ℃, calculated by mass percentage, the chemical composition of flux block I includes SiO2 60%, Al2O3 14%, Fe2O3 0.50%, TiO2 0.05%, CaO8%, MgO 0.30%, K2O 5%, Na2O 1.0%, ZrO2 0.30%, ZnO 0.60%, B2O3 8% and Ba0 0.50%, with the remainder being loss on ignition; the diameter of the glass fiber is 20 mm; the particle size of the pyrope stone powder is 150 μm; the particle size of the kyanite powder is: 60-70% on a 200 mesh sieve; the particle size of the zirconium silicate is: 0-0.5% on a 325 mesh sieve; the particle size of the waste porcelain powder is 160 μm; the chemical composition of the waste porcelain powder is: SiO2 70%, Al2O3 22%, Fe2O32%, TiO2 0.08%, CaO 0.5%, MgO 0.03%, K2O 3.0% and Na2O0.8%, the rest is loss on ignition;

[0115] C. Dry and polish the repair base layer in sequence to make the surface of the repair base layer flush with the surface of the pretreated ceramic;

[0116] D. Fill the repair glaze on the surface of the repair base and compact it to form a repair surface layer; the thickness of the repair surface layer is 4 μm; calculated by weight, the repair glaze includes 90 parts of glaze slurry I, 10 parts of glaze slurry II, 10 parts of fluxing block II and 0.5 parts of propylene glycol; calculated by weight, the glaze slurry I includes 25 parts of feldspar, 20 parts of quartz, 4 parts of dolomite, 8 parts of wollastonite, 10 parts of calcium carbonate, 6 parts of kaolin, 5 parts of calcined alumina, 2 parts of calcined zinc oxide and 9 parts of zirconium silicate; calculated by weight, the glaze slurry II includes 45 parts of feldspar, 20 parts of quartz, 30 parts of wollastonite and 10 parts of calcined zinc oxide; the particle size of fluxing block II is 130 μm, and the thermal expansion coefficient of fluxing block II is 2.5×10 -6 / ℃, calculated by mass percentage, the chemical composition of flux block II includes SiO2 60%, Al2O3 14%, Fe2O3 0.50%, TiO2 0.05%, CaO 8%, MgO 0.30%, K2O 5%, Na2O 1.0%, ZrO2 0.30%, ZnO 0.60%, B203 8% and Ba0 0.50%, and the rest is loss on ignition;

[0117] E. Place the pretreated ceramic with the repaired surface layer in a shuttle kiln, heat the shuttle kiln from room temperature to 1175-1185°C at a heating rate of 12°C / min and keep it warm for 24 hours, then cool it down to room temperature at a cooling rate of 12°C / min to complete the repair.

[0118] Comparative group

[0119] Comparative Example 1

[0120] The repair process and raw materials of Comparative Example 1 are the same as those of Example 1, except that glass fiber is not added to the repair base material formula in Comparative Example 1.

[0121] Comparative Example 2

[0122] The repair process and raw materials of Comparative Example 2 are the same as those of Example 1, except that no kyanite powder is added to the repair base material formula in Comparative Example 2.

[0123] Comparative Example 3

[0124] The repair process and raw materials of Comparative Example 3 are the same as those of Example 1, except that the fluxing block I and fluxing block II in the repair base material formula of Comparative Example 3 are fluxing blocks with a potassium oxide to sodium oxide ratio of 1:1.

[0125] The defects on the ceramic glaze surface were repaired using different repair processes in the above embodiments and comparative examples, and the repair effects of the defects on the ceramic glaze surface obtained by using different repair processes in the above embodiments and comparative examples were observed. The thermal shock resistance and firing shrinkage rate of the repair layer of the ceramic glaze surface were tested, and the test results are shown in Table 1 below.

[0126] Table 1 Performance test results of repair layers obtained by different repair processes

[0127]

[0128] A repair process for ceramic glaze defects has a low shrinkage rate and is not prone to cracking. It not only increases the range of repairable defects, but also makes the repaired ceramic glaze defects smooth and flat, and has no color difference from other parts of the ceramic glaze, ensuring aesthetics.

[0129] In Comparative Example 1, since no glass fiber is added, the strength and firing shrinkage of the repair base material are increased, and the strength and firing shrinkage after repair are increased, which in turn leads to unevenness and cracks in the repaired glaze surface and poor thermal shock resistance.

[0130] In Comparative Example 2, since no kyanite powder was added, the volume shrinkage of the flux component in the repair base material after high-temperature calcination could not be completely offset, resulting in a very large firing shrinkage rate. The repaired glaze surface was uneven and cracked, and had poor thermal shock resistance.

[0131] In Comparative Example 3, since flux block I and flux block II are flux blocks with a potassium oxide to sodium oxide ratio of 1:1, the strength and firing shrinkage rate after repair are increased. The increase in strength and firing shrinkage rate after repair makes the repaired glaze surface uneven and cracked, and has poor thermal shock resistance.

[0132] It should be noted that the repair layer refers to a repair layer composed of a repair base layer and a repair surface layer.

[0133] The technical principles of the present invention have been described above with reference to specific embodiments. These descriptions are intended solely to illustrate the principles of the present invention and are not to be construed in any way as limiting the scope of protection of the present invention. Based on the explanations herein, those skilled in the art will readily conceive of other specific embodiments of the present invention without inventive effort, and such embodiments will fall within the scope of protection of the present invention.

Claims

1. A process for repairing ceramic glaze defects, characterized in that: The following steps are involved: A. Grinding the defects of the ceramic into a U-shaped groove and wetting the U-shaped groove to obtain the pretreated ceramic; B. Filling the U-shaped groove of the pretreated ceramic with a repair base material and compacting it to obtain a repair base layer; wherein, calculated by weight, the repair base material comprises 30-40 parts of waste porcelain powder, 15-25 parts of pyrope powder, 25-35 parts of kyanite powder, 5-15 parts of fluxing block I, 2-10 parts of zirconium silicate, and 0.2-1 part of glass fiber, and the thermal expansion coefficient of the fluxing block I is (2-3)×10 -6 / ℃; C. drying and polishing the repair base layer in sequence so that the surface of the repair base layer is flush with the surface of the pretreated ceramic; D. filling the repair glaze on the surface of the repair base layer and compacting it to form a repair surface layer; E. Place the pretreated ceramic with the repaired surface layer in a shuttle kiln, heat the shuttle kiln from room temperature to 1175-1185°C at a heating rate of 10-15°C / min and keep it warm for 23-25 ​​hours, then cool it down to room temperature at a cooling rate of 10-15°C / min to complete the repair.

2. A ceramic glaze defect repair process according to claim 1, characterized in that: In step B, the repair primer further comprises sodium carboxymethyl cellulose solution, glycerol and a preservative; Calculated by mass, the repair base material includes 30-40 parts of waste porcelain powder, 15-25 parts of charcoal powder, 25-35 parts of kyanite powder, 5-15 parts of fluxing block I, 2-10 parts of zirconium silicate, 0.2-1 part of glass fiber, 2-6 parts of sodium carboxymethyl cellulose solution, 0.2-1 part of glycerol and 0.2-1 part of preservative.

3. A ceramic glaze defect repair process according to claim 2, characterized in that: In step D, the repair glaze includes 85-95 parts of glaze slurry I, 10-15 parts of glaze slurry II, 2-10 parts of fluxing block II and 0.2-0.5 parts of glycerol, calculated by weight; Calculated by weight, the top glaze slurry I includes 15-25 parts of feldspar, 20-30 parts of quartz, 3-5 parts of dolomite, 8-15 parts of wollastonite, 5-10 parts of calcium carbonate, 4-6 parts of kaolin, 3-5 parts of calcined alumina, 1-3 parts of calcined zinc oxide and 8-10 parts of zirconium silicate; Calculated by weight, the top glaze slurry II includes 40 to 50 parts of feldspar, 15 to 25 parts of quartz, 20 to 30 parts of wollastonite and 10 to 20 parts of calcined zinc oxide.

4. A ceramic glaze defect repair process according to claim 3, characterized in that: The particle size of the flux block I and the flux block II are both ≤160 μm; Calculated by mass percentage, the chemical compositions of the flux block I and the flux block II include SiO2 60-68%, Al2O3 6-14%, Fe2O3 0.10-0.50%, TiO2 0.01-0.05%, CaO 4-12%, MgO 0.15-0.5%, K2O 2-5%, Na2O 0.5-1.5%, ZrO2 0.10-0.50%, ZnO 0.20-0.60%, B2O3 8-12% and BaO0.30-0.60%, with the remainder being loss on ignition.

5. The process for repairing ceramic glaze defects according to claim 1, characterized in that: The diameter of the glass fiber is ≤30 mm.

6. The process for repairing ceramic glaze defects according to claim 1, characterized in that: In step B, the thickness of the repair bottom layer is 8 to 10 μm; In step D, the thickness of the repair surface layer is 3 to 5 μm.

7. The process for repairing ceramic glaze defects according to claim 1, characterized in that: The particle size of the coke gemstone powder is ≤200 μm; According to the mass percentage, the particle size of the kyanite powder is as follows: after passing through a 200-mesh sieve, the residue is 60-70%; According to mass percentage, the particle size of the zirconium silicate is: after passing through a 325-mesh sieve, the residue is 0-0.5%.

8. The process for repairing ceramic glaze defects according to claim 1, characterized in that: The particle size of the waste porcelain powder is ≤200 μm; Calculated by mass percentage, the chemical composition of the waste porcelain powder includes SiO2 65-73%, Al2O3 19-27%, Fe2O3 1-2%, TiO2 0.01-0.1%, CaO 0.5-1.5%, MgO 0.01-0.05%, K2O 2.5-3.5% and Na2O 0.5-1%, with the rest being loss on ignition.

9. The process for repairing ceramic glaze defects according to claim 1, characterized in that: The specific steps in step A are: first, use a carbon rod vibrating pen to grind the defects of the ceramic into a U-shaped groove, blow away the polished ceramic powder with an air gun, and then wipe and moisten the U-shaped groove with a wet towel to obtain pretreated ceramic.

10. The process for repairing ceramic glaze defects according to claim 3, characterized in that: In step B, the preparation method of the repair base material is as follows: after uniformly mixing the formulated amount of waste porcelain powder, coke sapphire powder, kyanite powder, flux block I and zirconium silicate, an intermediate slurry I is obtained; and then, after uniformly mixing the formulated amount of glass fiber, sodium carboxymethyl cellulose, glycerol and preservative, the intermediate slurry I is added, and the repair base material is obtained. In step D, the preparation method of the repair glaze is: after uniformly mixing the formulated amount of glaze slurry I, glaze slurry II and fluxing block II, an intermediate slurry II is obtained; and after uniformly mixing the formulated amount of propylene glycol into the intermediate slurry II, a repair glaze is obtained.

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