All-through Wear-resistant Special Granite Ceramic Tile with Phenocryst Effect and Its Preparation Method

Abstract

The present invention relates to a through-body wear-resistant special granite ceramic tile with a porphyritic effect and a preparation method thereof. The preparation method includes the steps of: (1) preparing a polycrystalline phase wear-resistant matrix body blank formula slurry; (2) preparing a high-transparency porphyritic body blank formula slurry; (3) preparing different color powder materials; (4) preparing different color granular materials; (5) preparing a mixed powder material; (6) performing through-body cloth laying; (7) pressing into shape; (8) drying; (9) spraying water; (10) preparing a color slurry; (11) performing slurry spraying decoration; (12) drying the decorative wear-resistant layer; (13) firing at a high temperature; (14) processing: obtaining a through-body wear-resistant special granite ceramic finished tile with a polished surface or a natural surface or a special-shaped surface. And a through-body wear-resistant special granite ceramic tile with a porphyritic effect is prepared by using the said preparation method.

Description

Technical Field

[0001] The present invention belongs to the technical field of ceramic tiles, and particularly relates to a through-body wear-resistant special granite ceramic tile with a porphyritic effect and a preparation method thereof. Background Art

[0002] Porphyritic granite, also known as granular granite, has other silicate crystal grain minerals of different sizes scattered in its granite background. These silicate crystals exist in a transparent or semi-transparent state, adding unique aesthetics to the stone. The internal grain minerals actually become the patterns of the stone. These patterns are naturally formed and form a strong contrast with the granite pattern, further enriching the visual effect of the stone texture. Common colors include gray, black, red, white, etc. There are white porphyritic spots in black stones, gray porphyritic spots in white stones, and black and white porphyritic spots in red stones. Porphyritic granite has obvious texture and a smooth surface, and is usually used for interior walls, floors, columns, countertops, etc. of buildings, and is one of the main building materials in high-end public places.

[0003] As a non-renewable resource, with the passage of time, porphyritic granite has begun to show a trend of resource depletion. In order to protect ore resources, the state has strictly controlled the exploitation of granite. This measure has had a huge impact on the building materials market for outdoor places. Therefore, people are urgently seeking a building material that can replace granite. At this time, granite tiles came into being. Granite tiles have both beauty, delicacy, practicality and effectiveness, and can be widely used in high-end building decoration projects such as villas, gardens, and communities, as well as public scenes with a large number of people such as leisure squares, municipal projects, landscaping, subway stations and railway stations. At the same time, no phenomena such as qualitative change and weathering of stone will occur during use.

[0004] However, the imitation porphyritic granite products prepared by process means such as cloth or granulation mixing generally have the problem of single texture pattern and cannot fully imitate the crystal spot texture effect of porphyritic granite. At present, the best imitation of the texture effect of porphyritic granite is the glazed ceramic products produced by decorative printing technologies such as inkjet or screen printing. However, the decorative pattern layer of conventional glazed tiles is generally within 0.1 mm, and a transparent glass glaze layer with a thickness of about 0.2 mm needs to be covered on its surface during use. The hardness of the glass glaze layer is relatively poor, and the underlying decorative layer is easily worn during use, resulting in the loss of surface pattern texture. It can be seen that there is a fatal defect in the application of granite glazed ceramic tiles in public places, that is, the wear resistance of their glazed surfaces is insufficient, and most of them can only be used as ordinary floor tiles. Therefore, the existing production technology of imitation porphyritic granite ceramic tiles still needs to be improved and developed. Summary of the Invention

[0005] Aiming at the deficiencies of the above-mentioned existing technologies, the technical problem to be solved by the present invention is to provide a high-hardness and wear-resistant decorative layer with a decorative layer thickness of 0.5 mm to 1.0 mm after high-temperature firing by combining a polycrystalline matrix body formula and a high-transparency porphyry formula, and applying digital spraying technology and full-body fabric technology. It can not only perfectly present the rich texture effect of porphyry granite stone materials, but also has ultra-long decorative durability and wear resistance, and can be widely applied to the full-body wear-resistant special granite ceramic tiles with porphyry effect in public places and their preparation methods.

[0006] The technical solution of the present invention is the preparation method of the full-body wear-resistant special granite ceramic tile with porphyry effect, which is characterized in that it includes the following steps:

[0007] ⑴ Preparation of polycrystalline wear-resistant matrix body formula slurry: The raw materials in the polycrystalline wear-resistant matrix body formula are proportioned and ball-milled, and after obtaining the polycrystalline wear-resistant body formula slurry, it is sent to the transfer slurry tank for storage and aging for later use;

[0008] ⑵ Preparation of high-transparency porphyry body formula slurry: The raw materials in the high-transparency porphyry body formula are proportioned and ball-milled, and after obtaining the high-transparency porphyry body formula slurry, it is sent to the transfer slurry tank for storage and aging for later use;

[0009] ⑶ Preparation of different color powders: According to the design requirements of the texture pattern, ceramic colorants or opacifiers with a set ratio are added to the polycrystalline wear-resistant matrix body formula slurry in step ⑴ and the high-transparency porphyry body formula slurry in step ⑵, and after stirring evenly, it is sent to the spray drying tower for powder making to obtain color powders and store them for aging for later use;

[0010] ⑷ Preparation of different color granular materials: Part of the color powders in step ⑶ are granulated by a granulating device to obtain different color granular materials;

[0011] ⑸ Preparation of mixed powders: The color powders in step ⑶ and the color granular materials in step ⑷ are mixed evenly according to the designed ratio to obtain mixed powders for standby;

[0012] ⑹ Full-body fabric: The mixed powders in step ⑸ are arranged in texture according to the design parameters through the full-body fabric forming system to obtain a blank layer with porphyry granite texture;

[0013] ⑺ Compression molding: The blank layer in step ⑹ is sent into the mold cavity of the molding mechanism for pressing to obtain a wear-resistant body layer;

[0014] ⑻ Drying: The formed wear-resistant body layer is sent into a roller kiln for drying, and the strength of the dried porcelain body is controlled at 1.5 - 2.5 Mpa;

[0015] ⑼ Spraying water: Spraying water on the surface of the wear-resistant body in step ⑻ for wetting;

[0016] ⑽ Preparation of color slurry: Based on the polycrystalline wear-resistant matrix green body formula in step ⑴ and the high-transparency spotted crystal green body formula in step ⑵, ceramic colorants and kaolin are introduced, and through the processing techniques of calcination, grinding, and spray drying, color slurry is obtained;

[0017] ⑾ Spray slurry decoration: On the surface of the wetted green body, digital spray slurry process decoration is carried out using the color slurry in step ⑽ according to the designed pattern to form a decorative wear-resistant layer;

[0018] ⑿ Drying of the decorative wear-resistant layer: The drying temperature is 100 - 200 °C, and the drying time is 3 - 8 min;

[0019] ⒀ High-temperature firing: The ceramic green body in step ⑿ is sent into a roller hearth kiln for firing;

[0020] ⒁ Processing: The fired semi-finished product is polished and edged or not polished and edged to finally obtain a polished surface or a natural surface or a special-shaped surface all-through wear-resistant special granite ceramic finished brick.

[0021] Preferably: The polycrystalline wear-resistant green body formula in step ⑴ is composed of the following raw material components by weight percentage: ball clay 8% - 15%, high-white kaolin 8% - 15%, mixed mud 10% - 15%, calcined talc 0% - 5%, bentonite 3 - 6%, potassium-sodium stone powder 15 - 25%, finely ground lithium tailings 8% - 15%, calcined bauxite 4% - 8%, fine corundum powder 15% - 25%, ultrafine zirconium silicate 0% - 5%, high-purity rutile titanium dioxide powder 0% - 5%, green body strengthening agent 0 - 1%, deflocculant 1 - 3%;

[0022] The polycrystalline wear-resistant green body formula is composed of the following chemical components by weight percentage: Al2O3 30 - 40 wt%, SiO2 45 - 55 wt%, K2O 1 - 3 wt%, Fe2O3 1 - 2 wt%, Na2O 1 - 3 wt%, CaO 0 - 0.5 wt%, MgO 0.5 - 2.5 wt%, loss on ignition 0 - 5 wt%;

[0023] The processing of the polycrystalline wear-resistant green body formula in step ⑴ adopts a wet ball milling process, and the median diameter D50 of its slurry is controlled to be 8.5 - 10.5 μm.

[0024] Preferably: The fine corundum powder is α - Al2O3 with an Al2O3 content of 99 - 100%, an Fe2O3 content of 0 - 1%, and a particle size D50 < 3 μm;

[0025] The chemical composition of the finely ground lithium tailings consists of the following components by weight percentage: Al2O3 15 - 20 wt%, SiO2 65 - 75 wt%, K2O 2 - 5 wt%, Fe2O3 0 - 4 wt%, Na2O 2 - 5 wt%, CaO 0 - 2 wt%, MgO 0 - 1 wt%, Li2O 0.3 - 1 wt%, trace elements 0 - 1 wt%, loss on ignition 0 - 5 wt%; the particle size D50 of the finely ground lithium tailings is between 4 μm and 8 μm; the trace elements include rubidium, gallium, strontium, cadmium, and nickel elements;

[0026] The ZrO2 content of the ultrafine zirconium silicate is > 64%, and the particle size D50 < 1 μm;

[0027] The high-purity anatase titanium dioxide powder is anatase titanium white with a TiO2 content > 98%, the whiteness value of the powder is ≥ 96%, the volatile matter at 105° ≤ 0.5%, the residue on a 325-mesh sieve < 0.1%, and the particle size D50 < 1 μm.

[0028] As a preference: The high-transparency spotted crystal green body formula in step (2) consists of the following raw material components by weight percentage: ultra-white ball clay 8% - 15%, ultra-white kaolin 8% - 15%, ultra-white calcined talc 0% - 5%, high-white bentonite 3 - 6%, high-white potassium sodium feldspar 15 - 25%, glass powder 10 - 20%, ultra-white lithium tailings powder 10% - 20%, barium carbonate 10% - 20%, green body strengthening agent 0 - 1%, deflocculant 1 - 3%;

[0029] The high-transparency spotted crystal green body formula consists of the following chemical components by weight percentage: Al2O3 15 - 20 wt%, SiO2 60 - 70 wt%, K2O 1 - 3 wt%, Fe2O3 0 - 0.5 wt%, Na2O 1 - 3 wt%, CaO 0 - 0.5 wt%, MgO 0.5 - 2.5 wt%, BaO 7 - 16 wt%, loss on ignition 0 - 8 wt%;

[0030] The whiteness of the high-transparency spotted crystal green body formula in step (2) is controlled at 70 - 80%, the light transmittance is controlled at 10 - 20%, and the high-transparency spotted crystal green body formula is processed using a wet ball milling process, and the median diameter D50 of the slurry is controlled at 8.5 - 10.5 μm;

[0031] The raw materials used in the high-transparency spotted crystal green body formula in step (2), namely ultra-white ball clay, ultra-white kaolin, ultra-white calcined talc, ultra-white bentonite, ultra-white lithium tailings powder, and high-white potassium sodium feldspar, are obtained by iron removal processing of ball clay, high-white kaolin, calcined talc, bentonite, potassium sodium feldspar powder, and finely ground lithium tailings. The number of iron removal times for the raw materials is 1 - 5 times, and the whiteness is controlled at 70 - 80%.

[0032] Preferably, the color powder in step (3) is composed of the following components by weight percentage: polycrystalline phase wear-resistant body formula slurry is 0-100wt%, high-transparency porphyritic body formula slurry is 0-100wt%, ceramic colorant is 0-5wt%, and opacifier is 0-10wt%; the color powder is provided with 2-10 different types of colors;

[0033] The ceramic colorant described in step (3) selects one of the following:

[0034] It is composed of the following components by weight percentage: cobalt blue: 0-100wt%, manganese red: 0-100wt%, apple green: 0-100wt%, chromium green: 0-100wt%, orange: 0-100wt%, praseodymium yellow: 0-100wt%, cobalt black: 0-100wt%;

[0035] It is composed of the following components by weight percentage: cobalt blue: 0-100wt%, vanadium zirconium blue: 0-100wt%, brown: 0-100wt%, encapsulated red: 0-100wt%, orange: 0-100wt%, encapsulated yellow: 0-100wt%, black: 0-100wt%, green: 0-100wt%;

[0036] The opacifier described in step (3) is composed of the following components by weight percentage: zirconia: 0-100wt%, zirconium silicate 0-100wt%, titanium dioxide: 0-100wt%;

[0037] The spray drying tower in step (3) adopts a pressure type spray drying system. The spray drying system uses a nozzle plate combination with a pore diameter of 1.5mm-2.0mm, an atomization pressure of 1.8MPa-2.6MPa. The particle size distribution of the obtained powder is that the proportion of particles larger than 20 mesh sieve is <6%, the proportion of particles between 20 mesh and 40 mesh is 20%-25%, the proportion of particles between 40 mesh and 60 mesh is 40%-45%, the proportion of particles between 60 mesh and 80 mesh is 15%-20%, the proportion of particles smaller than 80 mesh is <3%, and the specific gravity of the powder is 0.85-0.95g / cm 3 , the moisture content is controlled at 6-8%, and the angle of repose is controlled at 33°-38°.

[0038] Preferably, the granulating equipment described in step (4) includes a discharging device, a leveling device, a pressing roller, a cutter, and a conveyor belt, and is composed of several discharging devices arranged above the conveyor belt, a leveling device, a pressing roller, and a cutter arranged along the running direction of the conveyor belt behind the discharging device; the discharging device spreads the color powder materials described in step (3) in multiple layers on the surface of the conveyor belt according to the design parameters, and after being leveled to a fixed height by the leveling device according to the particle thickness requirement, it is pressed into blocks by the pressing roller, and finally transported to the cutter to be processed into color particle materials of different colors, sizes, and shapes for storage and standby; there are 2 to 6 kinds of the color particle materials, the particle size is controlled to be 3 to 20 mm, the thickness is controlled to be 1 to 10 mm, the flexural strength is controlled to be ≥0.1 Mpa, and the bulk density is controlled to be ≥1.0 g / cm 3 ; there are 2 to 6 kinds of the mixed powder materials described in step (5), and they are composed of the following components by weight percentage: color powder materials: 0 to 100 wt%, color particle materials: 0 to 100 wt%.

[0039] Preferably, the through-body cloth-forming system described in step (6) includes a through-body cloth platform, a pressing and forming platform, and a conveying mechanism; the through-body cloth platform is composed of a cloth mechanism, a transition belt arranged at the bottom of the cloth mechanism, a transition hopper whose traveling terminal is lower than the traveling position of the transition belt, a grille connected to the bottom of the transition hopper, a movable replenishing hopper and a transfer replenishing hopper arranged longitudinally above the conveying mechanism on the side of the pressing and forming platform; multiple groups of the cloth mechanisms are designed and arranged at the topmost part of the through-body cloth platform;

[0040] After the cloth mechanism completes cloth according to the designed texture pattern, a blank layer is formed. The blank layer is conveyed to the transition hopper by the transition belt, fixed by the grille, and then sent to the mold cavity in the pressing and forming platform arranged at the tail end of the through-body cloth platform through the conveying mechanism. After being replenished and leveled by the movable replenishing hopper, it is pressed and formed to obtain a wear-resistant blank layer;

[0041] The blank layer described in step (6) forms a granite pattern texture that is consistent from bottom to top by the through-body cloth-forming system, and its thickness can be controlled to be 18 mm to 80 mm.

[0042] Preferably, for the pressing and forming in step (7), the pressing pressure > 40 MPa / cm 2 , the thickness of the wear-resistant blank layer is controlled to be 9 mm to 40 mm; the drying time described in step (8) is 50 to 120 minutes; the residual moisture of the green body after drying ≤ 0.5%; the color slurry described in step (10) is composed of the following components by weight percentage: basic slurry 95 to 100%, ceramic colorant 0 to 5%, formulated by weight percentage, and ground into slurry using a wet ball milling process; the specific gravity of the color slurry is controlled to be 1.75 ± 0.5 g / cm 3, the viscosity at 40° is 60 to 150 mPa·s, and the D50 particle size is controlled to be 10 μm to 15 μm;

[0043] The base slurry is composed of the following components by weight percentage: lightly burned wear-resistant material: 0 to 90 wt%, lightly burned highly permeable material: 0 to 90 wt%, kaolin: 8 to 20 wt%, CMC: 0.2 to 1.0 wt%, melamine: 0.5 to 1.0 wt%, defoaming agent: 0.2 to 1.0 wt%;

[0044] The formulation compositions of the lightly burned wear-resistant material and the lightly burned highly permeable material are the same as the formulation of the polycrystalline wear-resistant green body in step (1) and the formulation of the highly permeable spotted crystal green body in step (2) respectively. The difference is that light burning processing is required; the light burning processing is to prepare the formulation according to the weight percentage, ball mill it into slurry by wet process, the moisture content of the slurry is 35 to 40%, the viscosity at 40° is 40 to 80 mPa·s, and the D50 particle size is 3 μm to 6 μm; spray dry the ball-milled slurry to obtain powder, put the obtained powder into a sagger made of refractory material or spread it flat on a plate made of refractory material, and fire it at a temperature of 1050 to 1150 °C to obtain the lightly burned wear-resistant material and the lightly burned highly permeable material.

[0045] Preferably: for the decorative wear-resistant layer in step (11), a numerical control spraying process is adopted, and it is decorated and printed using a variety of different color slurries according to the designed pattern texture. The digital spraying pattern is similar to the pattern texture of the wear-resistant green body layer, the pattern is narrowed by 0.2 mm to 0.4 mm, and the thickness of the decorative wear-resistant layer is 0 to 1 mm;

[0046] The digital spraying process in step (11) is to directly control the spraying process using digital information, and can simultaneously realize the spraying of 4 to 10 different color slurries, and the spraying amount per square meter is controlled to be 0 to 1800 g;

[0047] For the high-temperature firing in step (13), the firing temperature is 1180 to 1250 °C, the firing time is 60 to 120 minutes, the water absorption rate of the fired product is ≤0.5%, and the Ra value of the product out of the kiln. The Ra value refers to the arithmetic mean deviation of the profile, that is, the surface roughness is between 1.5 and 3 μm;

[0048] The processing in step (14) includes two cases. Case one is to directly grind the edge of the product fired in step (13); case two is to first polish the product obtained in step (13) and then grind the edge;

[0049] The polishing is for the wear-resistant layer: The polishing process parameters are as follows: the pressure of the polishing machine is below 0.6 Mpa, the polishing speed is 15 - 30 m / min, the polishing abrasive blocks are matched with 10 - 15 groups of 3000-mesh elastic abrasive blocks, 15 - 20 groups of 5000-mesh elastic abrasive blocks, 15 - 25 groups of 6000-mesh elastic abrasive blocks, 5 - 10 groups of 2000-mesh fiber abrasive blocks, 5 - 10 groups of 3000-mesh fiber abrasive blocks, the polishing cutting amount is less than 0.05 mm, and the Ra value of the product after polishing is ≤ 0.1 μm.

[0050] Another technical solution of the present invention is that the all-through wear-resistant special granite ceramic tile with porphyritic effect is characterized in that it is prepared by using the preparation method described in any one of the foregoing.

[0051] The third technical solution of the present invention is the polycrystalline phase wear-resistant green body of the all-through wear-resistant special granite ceramic tile with porphyritic effect, which is characterized in that the polycrystalline phase wear-resistant green body formula is composed of the following raw material components by weight percentage: ball clay 8% - 15%, high-white kaolin 8% - 15%, mixed mud 10% - 15%, calcined talc 0% - 5%, bentonite 3 - 6%, potassium-sodium stone powder 15 - 25%, finely ground lithium tailings 8% - 15%, calcined bauxite 4% - 8%, fine corundum powder 15% - 25%, ultrafine zirconium silicate 0% - 5%, high-purity anatase titanium dioxide powder 0% - 5%, green body enhancer 0 - 1%, deflocculant 1 - 3%;

[0052] The polycrystalline phase wear-resistant green body formula is composed of the following chemical components by weight percentage: Al2O3 30 - 40 wt%, SiO2 45 - 55 wt%, K2O 1 - 3 wt%, Fe2O3 1 - 2 wt%, Na2O 1 - 3 wt%, CaO 0 - 0.5 wt%, MgO 0.5 - 2.5 wt%, loss on ignition 0 - 5 wt%.

[0053] The fourth technical solution of the present invention is the high-transparency porphyritic green body of the all-through wear-resistant special granite ceramic tile with porphyritic effect, which is characterized in that the high-transparency porphyritic green body formula is composed of the following raw material components by weight percentage: ultra-white ball clay 8% - 15%, ultra-white kaolin 8% - 15%, ultra-white calcined talc 0% - 5%, high-white bentonite 3 - 6%, high-white potassium-sodium stone 15 - 25%, glass powder 10 - 20%, ultra-white lithium tailings powder 10% - 20%, barium carbonate 10% - 20%, green body enhancer 0 - 1%, deflocculant 1 - 3%;

[0054] The formula of the high-transparency porphyritic blank body is composed of the following chemical components by weight percentage: Al2O3 15-20wt%, SiO2 60-70wt%, K2O 1-3wt%, Fe2O3 0-0.5wt%, Na2O 1-3wt%, CaO 0-0.5wt%, MgO 0.5-2.5wt%, BaO 7-16wt%, and loss on ignition 0-8wt%.

[0055] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0056] ⑴ The present invention provides a through-body wear-resistant special granite ceramic tile with a porphyritic effect. For this porphyritic granite ceramic tile, a polycrystalline phase wear-resistant blank body formula is used as the matrix material. After high-temperature firing, a variety of high-hardness wear-resistant crystals including mullite, corundum, zircon, baddeleyite, quartz, cristobalite, rutile, anorthite, cordierite, etc. can be generated by reaction. These high-hardness wear-resistant crystals not only have a large variety but also a high content, thus improving the wear resistance of the product.

[0057] ⑵ The polycrystalline phase wear-resistant blank body formula of the present invention has the following advantages: ① A large amount of fine corundum powder is introduced into the formula. Through the fine-processed corundum powder, on the one hand, the aluminum content of the formula can be increased, and at the same time, the reaction activity of the blank body during the sintering process can be improved, thereby promoting the formation of wear-resistant crystals such as mullite, feldspar, and corundum. ② The lithium tailings are finely ground in the formula. In addition to containing conventional elements such as silicon, aluminum, potassium, and sodium, the lithium tailings also contain special elements such as rubidium, gallium, strontium, cadmium, and nickel and have a high SiO2 content. By fine grinding, the fluxing effect of trace elements can be promoted, and at the same time, the reaction activity of SiO2 can be improved, promoting the growth of quartz crystal phase. The introduction of lithium and the formation of quartz crystals can both improve the wear resistance of the granite ceramic tile. ③ Ultrafine zirconium silicate and titanium dioxide powder are introduced into the formula, which can promote the formation of zircon and rutile crystals. Zircon and rutile crystals are both substances with high hardness, which can better improve the wear resistance of the product.

[0058] ⑶ In order to achieve the effect of crystal spots in granite, the present invention has developed a high-transparency porphyritic formula with a whiteness of more than 70% and a light transmittance higher than 10%. A large amount of barium carbonate and potassium-sodium stone powder are introduced into the blank body formula. After high-temperature firing, more potassium-sodium-barium orthoclase, sanidine, etc. crystals with a light transmittance close to that of glass and amorphous materials can be generated by reaction. By further improving the raw material quality through multiple iron removal processes, crystal spot materials with higher whiteness and light transmittance can be obtained;

[0059] ⑷ The present invention provides a through-body fabricating production process and technology. By combining technologies such as particle preparation, powder mixing, and through-body fabricating, the preparation of through-body wear-resistant special ceramic tiles is completed, realizing the through-body decorative effect with consistent pattern textures inside and outside the product.

[0060] ⑸ The present invention provides a method for preparing a digital spraying decorative wear-resistant layer. By performing light burning preprocessing on the formulated materials, the growth of wear-resistant crystals is promoted, enabling the product to achieve or even exceed the surface hardness and wear resistance of natural granite. Description of the Drawings

[0061] Figure 1 It is a phase detection result diagram of the polycrystalline wear-resistant green body in Example 1 of the present invention;

[0062] Figure 2 It is a phase detection result diagram of the high-transparency porphyry material in Example 1 of the present invention;

[0063] Figure 3 It is a phase detection result diagram of the ceramic tile in Comparative Example 1;

[0064] Figure 4 It is a phase detection result diagram of the ceramic tile in Comparative Example 2

[0065] Figure 5 It is an effect diagram of the all-through wear-resistant special porphyry granite ceramic tile of the present invention;

[0066] Figure 6 It is a schematic diagram of the all-through body fabric forming system of the present invention.

[0067] Description of the Main Component Symbols:

[0068] Integral fabric platform 1 Fabric mechanism 11 Transition belt 12 Transition hopper 13 Grille 14 Transfer supplementary hopper 15 Movable supplementary hopper 16 Pressing and forming platform 2 Mold cavity 21 Conveyor mechanism 3 Detailed Embodiments

[0069] The present invention will be further described in detail below in conjunction with embodiments:

[0070] Example 1

[0071] The all-through wear-resistant special granite ceramic tile with porphyry effect described in this example mainly includes two parts: a wear-resistant green body layer and a decorative wear-resistant layer. The main production process technical route is as follows:

[0072] ⑴ Preparation of the polycrystalline wear-resistant matrix green body formula slurry: The raw materials in the green body formula are proportionally weighed and ball-milled. After obtaining the polycrystalline wear-resistant green body formula slurry, it is sent to the transfer slurry tank for storage and aging for later use;

[0073] The polycrystalline wear-resistant green body formula consists of the following raw material components by weight: ball clay 9.55%, high-white kaolin 10%, mixed mud 12%, calcined talc 4%, bentonite 4%, potassium-sodium stone powder 19%, finely ground lithium tailings 10%, calcined bauxite 5%, fine corundum powder 20%, ultrafine zirconium silicate 3%, high-purity anatase titanium dioxide powder 2%, green body strengthening agent 0.35%, and deflocculant 1.1%;

[0074] The polycrystalline wear-resistant green body formula consists of the following chemical components by weight percentage: Al2O3 37.52 wt%, SiO2 49.27 wt%, K2O 1.54 wt%, Fe2O3 0.66 wt%, Na2O 1.65 wt%, CaO 0.21 wt%, MgO 1.10 wt%, TiO2 1.98 wt%, ZrO2 1.93 wt%, loss on ignition 4.14 wt%;

[0075] The processing of the polycrystalline wear-resistant green body formula adopts a wet ball milling process, and the median diameter D50 of its slurry is 9.7 μm;

[0076] The fine corundum powder is α-Al2O3 with an Al2O3 content of 99.4%, an Fe2O3 content of 0.6%, and a particle size D50 of 1.86 μm;

[0077] The chemical composition of the finely ground lithium tailings consists of the following by weight percentage: Al2O3 17.83 wt%, SiO2 69.11 wt%, K2O 3.50 wt%, Fe2O3 0.68 wt%, Na2O 3.45 wt%, CaO 0.84 wt%, MgO 0.42 wt%, Li2O 0.41 wt%, trace elements: 0.18 wt%, loss on ignition 3.58 wt%;

[0078] The trace elements include special elements such as rubidium, gallium, strontium, cadmium, nickel, etc.; the particle size D50 of the finely ground lithium tailings is 5.4 μm;

[0079] The ZrO2 content of the ultrafine zirconium silicate is 64.8%, and the particle size D50 is 0.82 μm;

[0080] The high-purity anatase titanium dioxide powder is TiO2, anatase titanium white powder with a content of 98.6%, the whiteness value of the powder is 97.2%, the volatile matter at 105° is 0.3%, the residue on a 325-mesh sieve is 0.01%, and the particle size D50 is 0.93 μm.

[0081] ⑵ Preparation of the slurry for the high-transparency spotted crystal green body formula: The raw materials in the green body formula are proportioned and ball milled, and after obtaining the slurry for the high-transparency spotted crystal green body formula, it is sent to the transfer slurry tank for storage and aging for later use;

[0082] The high-transparency spotted crystal green body formula consists of the following raw material components by weight percentage: ultra-white ball clay 12%, ultra-white kaolin 12%, ultra-white calcined talc 3%, high-white bentonite 4%, high-white potassium-sodium feldspar 20%, glass powder 15%, ultra-white lithium tailings powder 17.3%, barium carbonate 15%, green body reinforcing agent 0.6%, deflocculant 1.1%;

[0083] The formula of the high-transparency porphyritic body blank is composed of the following chemical components by weight: Al2O3 16.12 wt%, SiO2 57.82 wt%, K2O 1.78 wt%, Fe2O3 0.14 wt%, Na2O 3.97 wt%, CaO 0.25 wt%, MgO 1.25 wt%, BaO 11.69 wt%, loss on ignition 6.98 wt%.

[0084] The whiteness of the formula of the high-transparency porphyritic body blank is 76%, the light transmittance is controlled at 16.3%, and the wet ball milling process is used for processing the formula of the high-transparency porphyritic body blank. The median diameter D50 of the slurry is 9.3 μm.

[0085] The ball clay, high-white kaolin, calcined talc, bentonite, potassium-sodium stone powder, and finely ground lithium tailings are subjected to the iron removal process 3 times to obtain ultra-white ball clay with a whiteness of 72%; ultra-white kaolin with a whiteness of 74%; calcined talc with a whiteness of 77%; ultra-white bentonite with a whiteness of 73%; ultra-white potassium-sodium stone powder with a whiteness of 79%, and ultra-white lithium tailings powder with a whiteness of 81%.

[0086] ⑶ Preparation of different color powders: According to the design requirements of the texture pattern, a certain proportion of ceramic colorants or opacifiers are added to the slurry of the polycrystalline phase wear-resistant body blank formula in step ⑴ and the slurry of the high-transparency porphyritic body blank formula in step ⑵, and after stirring evenly, it is sent to a spray drying tower for powder making to obtain color powders and store them for aging;

[0087] Eight kinds of color powders are set, and the specific settings are as follows:

[0088] The white color powder is composed of the following components by weight percentage: 90 wt% of the slurry of the polycrystalline phase wear-resistant body blank formula, 10 wt% of the opacifier; among which the opacifier is composed of the following components by weight percentage: 20 wt% of zirconia, 55 wt% of zirconium silicate, and 25 wt% of titanium dioxide;

[0089] The light apricot color powder is composed of the following components by weight percentage: 100 wt% of the slurry of the high-transparency porphyritic body blank formula;

[0090] The gray color powder is composed of the following components by weight percentage: 99.7 wt% of the slurry of the polycrystalline phase wear-resistant body blank formula, 0.2 wt% of cobalt black colorant, and 0.1 wt% of orange colorant;

[0091] The light green color powder is composed of the following components by weight percentage: 99.8 wt% of the slurry of the high-transparency porphyritic body blank formula, 0.18 wt% of apple green colorant, and 0.02 wt% of chromium green colorant;

[0092] The black color powder is composed of the following components by weight percentage: 98.8 wt% of the slurry of the polycrystalline phase wear-resistant body blank formula, 1.1 wt% of cobalt black colorant, and 0.1 wt% of manganese red colorant;

[0093] The brown color powder consists of the following components by weight percentage: 97.3 wt% of the polycrystalline wear-resistant green body formula slurry, 0.4 wt% of cobalt black pigment, 0.7 wt% of praseodymium yellow pigment, and 1.6 wt% of manganese red pigment;

[0094] The light yellow color powder consists of the following components by weight percentage: 99.4 wt% of the high-transparency porphyritic green body formula slurry, 0.4 wt% of orange pigment, and 0.2 wt% of praseodymium yellow pigment;

[0095] The red color powder consists of the following components by weight percentage: 98.4 wt% of the polycrystalline wear-resistant green body formula slurry, 1.3 wt% of manganese red pigment, and 0.3 wt% of praseodymium yellow pigment;

[0096] The spray drying tower adopts a pressure-type spray drying system. The above pressure-type spray drying system uses a nozzle plate with a pore diameter of 1.8 mm and an atomization pressure of 2.2 MPa. The particle size distribution of the obtained powder is as follows: the proportion of particles larger than 20 mesh is 2.5%, the proportion of particles between 20 mesh and 40 mesh is 23.4%, the proportion of particles between 40 mesh and 60 mesh is 41.9%, the proportion of particles between 60 mesh and 80 mesh is 17.2%, the proportion of particles smaller than 80 mesh is 0.85%, and the powder specific gravity is 0.92 g / cm 3 , the moisture content is controlled at 6.5%, and the angle of repose is controlled at 35°.

[0097] ⑷ Preparation of different color granular materials: Part of the color powder in step ⑶ is granulated by a granulating device to obtain different color granular materials;

[0098] There are 5 types of the color granular materials, specifically white granules, black granules, brown granules, light apricot granules, and light yellow granules;

[0099] The granulating device includes 5 parts: a discharging device, a leveling device, a pressing roller, a cutting knife, and a conveyor belt. It can prepare granules with various effects, colors, thicknesses, and specifications. It consists of several discharging devices arranged above the conveyor belt, a leveling device, a pressing roller, and a cutting knife arranged along the running direction of the conveyor belt behind the discharging device. The discharging device spreads a total of 5 different color powders, namely white color powder, black color powder, brown color powder, light apricot color powder, and light yellow color powder in step ⑶ on the surface of the conveyor belt in multiple layers according to the design parameters. After being leveled to a fixed height by the leveling device according to the particle thickness requirement, it is pressed into a block by the pressing roller, and finally transported to the cutting knife to be processed into color granular materials of different colors, sizes, and shapes for storage and standby.

[0100] The size of the color granular material is 3 - 10 mm: the thickness is 5 mm, the flexural strength is 0.12 Mpa, and the bulk density is 1.61 g / cm 3 .

[0101] ⑸ Preparation of mixed powder: Mix the color powder in step ⑶ and the color granular material in step ⑷ evenly according to the designed ratio to obtain the mixed powder for standby;

[0102] Four types of the mixed powder are set according to the design requirements. Specifically,

[0103] The A mixed powder is composed of the following components by weight percentage: 10wt% of white granules, 5wt% of black granules, 30wt% of light apricot color powder, and 55wt% of gray color powder;

[0104] The B mixed powder is composed of the following components by weight percentage: 8wt% of brown granules, 15wt% of light yellow granules, 5wt% of white granules, 3wt% of black color powder, and 69wt% of gray color powder;

[0105] The C mixed powder is composed of the following components by weight percentage: 5wt% of brown granules, 20wt% of light apricot granules, 10wt% of white granules, 15wt% of red color powder, 40wt% of gray color powder, and 10wt% of light green color powder;

[0106] The D mixed powder is composed of the following components by weight percentage: 15wt% of light yellow color powder, 35wt% of light apricot color powder, 3wt% of black color powder, and 47wt% of gray color powder.

[0107] ⑹ Through-body cloth laying: Lay the mixed powder in step ⑸ through the through-body cloth laying forming system according to the design parameters to obtain a blank layer with porphyritic granite texture;

[0108] Please refer to Figure 6 As shown, the through-body cloth laying forming system includes a through-body cloth laying platform 1, a pressing and forming platform 2, and a conveying mechanism 3; the through-body cloth laying platform consists of a cloth laying mechanism 11, a transition belt 12, a transition hopper 13, a grille 14, a transfer feeding hopper 15, and a movable feeding hopper 16. There are 6 groups of the cloth laying mechanisms 11, which are arranged at the top of the through-body cloth laying platform 1. After the cloth laying mechanism 11 completes the cloth laying according to the designed texture pattern, a blank layer is formed. The blank layer is conveyed by the transition belt 12 to the transition hopper 13, fixed by the grille 14, and then sent to the mold cavity 21 in the pressing and forming platform 2 arranged at the tail end of the through-body cloth laying platform 1 through the conveying mechanism 3. After being filled and leveled by the movable feeding hopper 16, it is pressed and formed to obtain a wear-resistant blank layer;

[0109] The blank layer is formed with a granite pattern texture that is consistent from bottom to top by the through-body cloth laying forming system, and its thickness can be controlled to 80mm.

[0110] ⑺ Compression molding: Feed the blank layer from step ⑹ into the mold cavity of the molding mechanism for pressing to obtain a wear-resistant blank layer;

[0111] The pressing pressure for the compression molding is 45 MPa / cm 3 , and the wear-resistant blank layer has a thickness of 20 mm.

[0112] ⑻ Drying: Feed the formed wear-resistant blank layer into a roller hearth kiln for drying, and control the strength of the dried porcelain blank to 2.2 Mpa;

[0113] The drying time is 110 minutes; the residual moisture content of the green body after drying is 0.42%;

[0114] ⑼ Spraying water: Spray water on the surface of the wear-resistant blank in step ⑻ for wetting;

[0115] ⑽ Preparation of color slurry: Based on the polycrystalline wear-resistant matrix blank formula in step ⑴ and the high-transparency spotted crystal blank formula in step ⑵, introduce pigments and raw materials such as ceramic colorants and kaolin, and obtain color slurry through processing techniques such as calcination, grinding, and spray drying;

[0116] The color slurry is ground into slurry using a wet ball milling process, with a specific gravity of 1.75 g / cm 3 , a viscosity of 60 mPa·s at 40°, and the D50 particle size is controlled to 12 μm;

[0117] Eight types of color slurries are set according to design requirements, specifically including:

[0118] Color slurry 1 is composed of the following components by weight percentage: 99 wt% of wear-resistant base slurry and 1 wt% of cobalt blue colorant;

[0119] Color slurry 2 is composed of the following components by weight percentage: 97 wt% of wear-resistant base slurry and 3 wt% of vanadium zirconium blue colorant;

[0120] Color slurry 3 is composed of the following components by weight percentage: 98 wt% of wear-resistant base slurry and 2 wt% of brown colorant;

[0121] Color slurry 4 is composed of the following components by weight percentage: 98 wt% of high-transparency base slurry and 2 wt% of encapsulated red colorant;

[0122] Color slurry 5 is composed of the following components by weight percentage: 97 wt% of wear-resistant base slurry and 3 wt% of orange colorant;

[0123] Color slurry 6 is composed of the following components by weight percentage: 97 wt% of high-transparency base slurry and 3 wt% of encapsulated yellow colorant;

[0124] The color slurry 7 is composed of the following components by weight percentage: wear-resistant base slurry 99wt%, black pigment 1wt%;

[0125] The color slurry 8 is composed of the following components by weight percentage: high-transparency slurry 98wt%, green pigment 2wt%;

[0126] The wear-resistant base slurry is composed of the following components by weight percentage: lightly burned wear-resistant material 89.2%, kaolin 9.52%, CMC 0.32%, melamine 0.56%, defoaming agent 0.4%;

[0127] The formula composition of the lightly burned wear-resistant material is the same as that of the polycrystalline wear-resistant green body in step (1), except that it needs to be lightly burned. The lightly burning process is as follows: after the formula is prepared by weight percentage, it is ball-milled into slurry according to the wet process, the slurry moisture is 36%, the viscosity at 40° is 60 mPa·s, and the D50 particle size is 4 μm; the ball-milled slurry is spray-dried to obtain powder, and the obtained powder is filled into a sagger made of refractory material and fired at a temperature of 1080°C to obtain the lightly burned wear-resistant material;

[0128] The high-transparency base slurry is composed of the following components by weight percentage: lightly burned high-transparency material 89.2%, kaolin 9.52, CMC 0.32%, melamine 0.56%, defoaming agent 0.4%;

[0129] The formula composition of the lightly burned high-transparency material is the same as that of the high-transparency porphyritic green body in step (2), except that it needs to be lightly burned. The lightly burning process is as follows: after the formula is prepared by weight percentage, it is ball-milled into slurry according to the wet process, the slurry moisture is 36%, the viscosity at 40° is 60 mPa·s, and the D50 particle size is 4 μm; the ball-milled slurry is spray-dried to obtain powder, and the obtained powder is filled into a sagger made of refractory material and fired at a temperature of 1050°C to obtain the lightly burned high-transparency material;

[0130] ⑾ Spray slurry decoration: On the surface of the wetted green body, use the color slurry in step (10) for digital spray slurry process decoration according to the designed pattern to form a decorative wear-resistant layer;

[0131] The decorative wear-resistant layer is formed by decorative spraying with 8 different color slurries according to the designed pattern texture using the numerical control spray slurry process. The digital spray slurry pattern is similar to the pattern texture of the wear-resistant green body layer, the pattern is narrowed by 0.2 mm, and the thickness of the decorative wear-resistant layer is 0.8 mm.

[0132] The digital spray slurry process is a process that directly controls spraying using digital information, and the spraying amount per square meter is 1400 g;

[0133] ⑿ Drying of the decorative wear-resistant layer: Dry the decorative wear-resistant layer in step (11), the drying temperature is 150°C, and the drying time is 8 min;

[0134] ⒀ High-temperature firing: Feed the ceramic green body from step ⑿ into a roller hearth kiln for firing;

[0135] For the said high-temperature firing, the firing temperature is 1220 °C, the firing time is 75 minutes, the water absorption rate of the fired product is 0.06%, and the Ra value of the product out of the kiln is 1.72 μm;

[0136] ⒁ Processing: Polish and edge-grind the fired semi-finished product to finally obtain a polished all-through wear-resistant special granite ceramic finished brick.

[0137] For the said processing, specifically, first polish the product obtained in step ⒀ and then edge-grind it. The polishing is for the decorative wear-resistant layer. The polishing process parameters are: the pressure of the polishing machine is 0.4 Mpa, the polishing speed is 20 m / min, and the polishing abrasive block combination is: 12 groups of 3000-mesh elastic abrasive blocks, 18 groups of 5000-mesh elastic abrasive blocks, 20 groups of 6000-mesh elastic abrasive blocks, 6 groups of 2000-mesh fiber abrasive blocks, 8 groups of 3000-mesh fiber abrasive blocks, the polishing cutting amount is 0.042 mm, and the Ra value of the product after polishing is 0.052 μm.

[0138] Comparative Example 1

[0139] An all-through wear-resistant special granite ceramic brick with a porphyritic effect, the green body formula of which consists of the following components by weight percentage (ordinary green body formula): 20% of 35# stone powder, 28% of ultra-white washed mud, 24% of potassium-sodium stone powder, 10% of water abrasive, 3% of strong plastic clay, 5% of talc particles, 8.25% of ordinary mud paste, 0.45% of green body reinforcing agent, 1.3% of deflocculant;

[0140] The difference between Comparative Example 1 and Example 1 is that the polycrystalline phase wear-resistant green body formula in Example 1 is replaced with an ordinary green body formula. The preparation method of Comparative Example 1 is the same as that of Example 1.

[0141] Specifically, use the methods of Example 1 and Comparative Example 1 to prepare all-through wear-resistant special granite ceramic bricks respectively, and conduct wear depth, flexural strength, water absorption rate, and Mohs hardness performance tests on the obtained ceramic bricks and polished natural granite according to the national standard test method or the conventional test method of ceramic bricks. The results are shown in Table 1 below:

[0142] Table 1 Example 1, Comparative Example 1 and natural granite (polished surface)

[0143]

[0144] From the test results of Example 1, Comparative Example 1 and polished natural granite, it can be seen that when the polycrystalline phase wear-resistant green body formula in the present invention is replaced with an ordinary green body formula, the wear resistance, Mohs hardness and flexural strength of the prepared ceramic plate will decrease significantly. FromFigure 1 and Figure 2 From the phase detection results of Figure 2 , it can be seen that using the polycrystalline phase wear-resistant body formula generates more crystal phases than the ordinary body formula, including mullite, corundum, zircon, baddeleyite, quartz, cristobalite, rutile, anorthite, cordierite and other high-hardness wear-resistant crystals. Not only are there many types of crystal phases, but the content is also high. Therefore, the wear resistance of the granite ceramics prepared according to Example 1 is significantly higher than that of Comparative Example 1 and natural granite.

[0145] Comparative Example 2

[0146] The all-through wear-resistant special granite ceramic tile with porphyritic effect mainly includes two parts: a wear-resistant body layer and a decorative wear-resistant layer. The main production process technical route is as follows:

[0147] ⑴ Preparation of polycrystalline phase wear-resistant matrix body formula slurry: Weigh and ball mill the raw materials in the body formula in proportion, and send the obtained polycrystalline phase wear-resistant body formula slurry to the transfer slurry tank for storage and aging for later use;

[0148] The polycrystalline phase wear-resistant body formula is composed of the following raw material components by weight: ball clay 9.55%, high-white kaolin 10%, mixed mud 12%, calcined talc 4%, bentonite 4%, potassium-sodium stone powder 19%, finely ground lithium tailings 10%, calcined bauxite 5%, fine corundum powder 20%, ultrafine zirconium silicate 3%, high-purity anatase titanium dioxide powder 2%, body enhancer 0.35%, deflocculant 1.1%;

[0149] The polycrystalline phase wear-resistant body formula is composed of the following chemical components by weight percentage: Al2O3 37.52wt%, SiO2 49.27wt%, K2O 1.54wt%, Fe2O3 0.66wt%, Na2O 1.65wt%, CaO 0.21wt%, MgO 1.10wt%, TiO2 1.98wt%, ZrO2 1.93 wt%, loss on ignition 4.14wt%;

[0150] The processing of the polycrystalline phase wear-resistant body formula adopts a wet ball milling process, and the median diameter D50 of its slurry is 9.7μm;

[0151] The fine corundum powder is α-Al2O3 with an Al2O3 content of 99.4% and an Fe2O3 content of 0.6%, and the particle size D50 is 1.86μm;

[0152] The chemical composition of the finely ground lithium tailings, by weight percentage, is as follows: Al2O3 17.83 wt%, SiO2 69.11 wt%, K2O 3.50 wt%, Fe2O3 0.68 wt%, Na2O 3.45 wt%, CaO 0.84 wt%, MgO 0.42 wt%, Li2O 0.41 wt%, trace elements 0.18 wt%, and loss on ignition 3.58 wt%. The trace elements include special elements such as rubidium, gallium, strontium, cadmium, nickel, etc.; the particle size D50 of the finely ground lithium tailings is 5.4 μm;

[0153] The ZrO2 content of the ultrafine zirconium silicate is 64.8%, and the particle size D50 is 0.82 μm;

[0154] The high-purity anatase titanium dioxide powder is TiO2, anatase titanium white powder with a content of 98.6%, the whiteness value of the powder is 97.2%, the volatile matter at 105° is 0.3%, the residue on a 325-mesh sieve is 0.01%, and the particle size D50 is 0.93 μm.

[0155] ⑵ Preparation of the high-transparency spotted crystal body formula slurry: Weigh and ball-mill the raw materials in the body formula in proportion, and after obtaining the high-transparency spotted crystal body formula slurry, send it to the transfer slurry tank for storage and aging for later use;

[0156] The high-transparency spotted crystal body formula consists of the following raw material components by weight percentage: ultra-white ball clay 12%, ultra-white kaolin 12%, ultra-white calcined talc 3%, high-white bentonite 4%, high-white potassium-sodium feldspar 20%, glass powder 15%, ultra-white lithium tailings powder 17.3%, barium carbonate 15%, body strengthening agent 0.6%, and peptizing agent 1.1%;

[0157] The high-transparency spotted crystal body formula consists of the following chemical components by weight parts: Al2O3 16.12 wt%, SiO2 57.82 wt%, K2O 1.78 wt%, Fe2O3 0.14 wt%, Na2O 3.97 wt%, CaO 0.25 wt%, MgO 1.25 wt%, BaO 11.69 wt%, and loss on ignition 6.98 wt%;

[0158] The whiteness of the high-transparency spotted crystal body formula is 76%, the light transmittance is controlled at 16.3%, and the high-transparency spotted crystal body formula is processed using a wet ball-milling process, and the median diameter D50 of the slurry is 9.3 μm.

[0159] The ball clay, high-white kaolin, calcined talc, bentonite, potassium-sodium feldspar powder, and finely ground lithium tailings are subjected to the iron removal process three times to obtain the raw materials ultra-white ball clay with a whiteness of 72%; ultra-white kaolin with a whiteness of 74%; calcined talc with a whiteness of 77%; ultra-white bentonite with a whiteness of 73%; ultra-white potassium-sodium feldspar powder with a whiteness of 79%; and ultra-white lithium tailings powder with a whiteness of 81%.

[0160] ⑶ Preparation of powders of different colors: According to the requirements of texture pattern design, a certain proportion of ceramic colorants or opacifiers is added to the slurries of the polycrystalline wear-resistant green body formula in step ⑴ and the high-transparency spotted crystal green body formula in step ⑵. After being stirred evenly, they are sent to a spray drying tower for powder making, and the colored powders are obtained and stored for aging before use;

[0161] Eight kinds of the colored powders are set as follows:

[0162] The white colored powder is composed of the following components by weight percentage: 90 wt% of the slurry of the polycrystalline wear-resistant green body formula, and 10 wt% of the opacifier; among which the opacifier is composed of the following components by weight percentage: 20 wt% of zirconia, 55 wt% of zirconium silicate, and 25 wt% of titanium dioxide;

[0163] The light apricot colored powder is composed of the following components by weight percentage: 100 wt% of the slurry of the high-transparency spotted crystal green body formula;

[0164] The gray colored powder is composed of the following components by weight percentage: 99.7 wt% of the slurry of the polycrystalline wear-resistant green body formula, 0.2 wt% of cobalt black colorant, and 0.1 wt% of orange yellow colorant;

[0165] The light green colored powder is composed of the following components by weight percentage: 99.8 wt% of the slurry of the high-transparency spotted crystal green body formula, 0.18 wt% of apple green colorant, and 0.02 wt% of chromium green colorant;

[0166] The black colored powder is composed of the following components by weight percentage: 98.8 wt% of the slurry of the polycrystalline wear-resistant green body formula, 1.1 wt% of cobalt black colorant, and 0.1 wt% of manganese red colorant;

[0167] The brown colored powder is composed of the following components by weight percentage: 97.3 wt% of the slurry of the polycrystalline wear-resistant green body formula, 0.4 wt% of cobalt black colorant, 0.7 wt% of praseodymium yellow colorant, and 1.6 wt% of manganese red colorant;

[0168] The light yellow colored powder is composed of the following components by weight percentage: 99.4 wt% of the slurry of the high-transparency spotted crystal green body formula, 0.4 wt% of orange yellow colorant, and 0.2 wt% of praseodymium yellow colorant;

[0169] The red colored powder is composed of the following components by weight percentage: 98.4 wt% of the slurry of the polycrystalline wear-resistant green body formula, 1.3 wt% of manganese red colorant, and 0.3 wt% of praseodymium yellow colorant;

[0170] The spray drying tower adopts a pressure spray drying system. The above pressure spray drying system uses a nozzle plate with an aperture of 1.8 mm, an atomization pressure of 2.2 MPa, and the particle size distribution of the powder obtained is as follows: the proportion of particles larger than 20 mesh is 2.5%, the proportion of particles between 20 mesh and 40 mesh is 23.4%, the proportion of particles between 40 mesh and 60 mesh is 41.9%, the proportion of particles between 60 mesh and 80 mesh is 17.2%, the proportion of particles smaller than 80 mesh is 0.85%, and the specific gravity of the powder is 0.92 g / cm 3 , the moisture content is controlled at 6.5%, and the angle of repose is controlled at 35°;

[0171] (4) Preparation of colored particle materials: A part of the colored powder in step (3) is granulated by a granulating device to obtain different colored particle materials;

[0172] Five kinds of the colored particle materials are provided, specifically white particles, black particles, brown particles, light apricot particles, and light yellow particles;

[0173] The granulating device includes five parts: a discharging device, a leveling device, a pressure roller, a cutter, and a conveyor belt. It can prepare particles with various effects, colors, thicknesses, and specifications, and is composed of several discharging devices arranged above the conveyor belt, a leveling device, a pressure roller, and a cutter arranged along the running direction of the conveyor belt behind the discharging device; The discharging device spreads a total of five different colored powders, namely white colored powder, black colored powder, brown colored powder, light apricot colored powder, and light yellow colored powder in step (3) on the surface of the conveyor belt in multiple layers according to the design parameters. After being leveled to a fixed height by the leveling device according to the particle thickness requirement, it is pressed into a block by the pressure roller, and finally transported to the cutter to be processed into colored particle materials of different colors, sizes, and shapes for storage and standby;

[0174] The size of the colored particle material is 3 - 10 mm: the thickness is 5 mm, the flexural strength is 0.12 Mpa, and the bulk density is 1.61 g / cm 3 ;

[0175] (5) Preparation of mixed powder: The colored powder in step (3) and the colored particle materials in step (4) are mixed evenly according to the designed ratio to obtain the mixed powder for standby;

[0176] Four kinds of the mixed powder are provided according to the design requirements; specifically,

[0177] The A mixed powder is composed of the following components by weight percentage: 10 wt% white particles, 5 wt% black particles, 30 wt% light apricot colored powder, and 55 wt% gray colored powder;

[0178] The B mixed powder consists of the following components by weight percentage: 8 wt% brown granules, 15 wt% light yellow granules, 5 wt% white granules, 3 wt% black color powder, and 69 wt% gray color powder;

[0179] The C mixed powder consists of the following components by weight percentage: 5 wt% brown granules, 20 wt% light apricot granules, 10 wt% white granules, 15 wt% red color powder, 40 wt% gray color powder, and 10 wt% light green color powder;

[0180] The D mixed powder consists of the following components by weight percentage: 15 wt% light yellow color powder, 35 wt% light apricot color powder, 3 wt% black color powder, and 47 wt% gray color powder.

[0181] ⑹ Through-body cloth: The mixed powder in step ⑸ is arranged with textures according to the design parameters through the through-body cloth forming system to obtain a blank layer with porphyritic granite texture;

[0182] Please refer to Figure 6 As shown, the through-body cloth forming system includes a through-body cloth platform 1, a pressing and forming platform 2, and a conveying mechanism 3; the through-body cloth platform consists of a cloth mechanism 11, a transition belt 12, a transition hopper 13, a grille 14, a transfer feeding hopper 15, and a movable feeding hopper 16. There are 6 groups of the cloth mechanisms 11, which are arranged at the top of the through-body cloth platform 1. After the cloth mechanism 11 completes the cloth according to the designed texture pattern, a blank layer is formed. The blank layer is conveyed by the transition belt 12 to the transition hopper 13, fixed by the grille 14, and then sent to the mold cavity 21 in the pressing and forming platform 2 arranged at the end of the through-body cloth platform 1 through the conveying mechanism 3. After being filled and leveled by the movable feeding hopper 16, it is pressed and formed to obtain a wear-resistant blank layer;

[0183] The blank layer forms a uniform granite pattern texture from the bottom to the top by the through-body cloth forming system, and its thickness can be controlled to 80 mm;

[0184] ⑺ Pressing and forming: The blank layer in step ⑹ is sent into the mold cavity of the forming mechanism for pressing to obtain a wear-resistant blank layer;

[0185] The pressing pressure for the pressing and forming is 45 MPa / cm 3 , and the wear-resistant blank layer is 20 mm thick;

[0186] ⑻ Drying: The formed wear-resistant blank layer is sent into a roller kiln for drying, and the strength of the dried porcelain blank is controlled to 2.2 Mpa;

[0187] The drying time is 110 minutes; the residual moisture content of the dried green body is 0.42%;

[0188] ⑼ Spraying water: Spraying water on the surface of the wear-resistant green body in step ⑻ for wetting;

[0189] ⑽ Preparation of color slurry: Based on the polycrystalline wear-resistant matrix green body formula in step ⑴ and the high-transparency spotted crystal green body formula in step ⑵, introducing pigments and raw materials such as ceramic colorants and kaolin, and obtaining color slurry through processing techniques such as calcination, grinding, and spray drying;

[0190] The color slurry is ground into slurry using a wet ball milling process, with a specific gravity of 1.75 g / cm 3 , a viscosity of 60 mPa·s at 40°, and a D50 particle size controlled at 12 μm;

[0191] Eight kinds of color slurries are set according to design requirements, specifically including:

[0192] Color slurry 1 is composed of the following components by weight percentage: 99 wt% of wear-resistant base slurry and 1 wt% of cobalt blue colorant;

[0193] Color slurry 2 is composed of the following components by weight percentage: 97 wt% of wear-resistant base slurry and 3 wt% of vanadium zirconium blue colorant;

[0194] Color slurry 3 is composed of the following components by weight percentage: 98 wt% of wear-resistant base slurry and 2 wt% of brown colorant;

[0195] Color slurry 4 is composed of the following components by weight percentage: 98 wt% of high-transparency base slurry and 2 wt% of encapsulated red colorant;

[0196] Color slurry 5 is composed of the following components by weight percentage: 97 wt% of wear-resistant base slurry and 3 wt% of orange colorant;

[0197] Color slurry 6 is composed of the following components by weight percentage: 97 wt% of high-transparency base slurry and 3 wt% of encapsulated yellow colorant;

[0198] Color slurry 7 is composed of the following components by weight percentage: 99 wt% of wear-resistant base slurry and 1 wt% of black colorant;

[0199] Color slurry 8 is composed of the following components by weight percentage: 98 wt% of high-transparency slurry and 2 wt% of green colorant;

[0200] The wear-resistant base slurry is composed of the following components by weight percentage: ball clay 9.55%, high-white kaolin 10%, mixed mud 12%, calcined talc 4%, bentonite 4%, potassium-sodium stone powder 19%, finely ground lithium tailings 10%, calcined bauxite 5%, fine corundum powder 20%, ultrafine zirconium silicate 3%, high-purity anatase titanium dioxide powder 2%, body enhancer 0.35%, and deflocculant 1.1%; after formulating according to the weight percentage, it is ball-milled into a base slurry by a wet process, with the mud moisture of 36%, the viscosity at 40° of 60 mPa·s, and the D50 particle size of 4 μm;

[0201] ⑾ Spray slurry decoration: On the surface of the wetted green body, use the color slurry in step ⑽ for digital spray slurry process decoration according to the designed pattern to form a decorative wear-resistant layer;

[0202] The decorative wear-resistant layer is formed by decorative spraying and printing with 8 different color slurries according to the designed pattern texture using a numerical control spray slurry process. The digital spray slurry pattern is similar to the pattern texture of the wear-resistant green body layer, with the pattern narrowing by 0.2 mm, and the thickness of the decorative wear-resistant layer is 0.8 mm.

[0203] The digital spray slurry process is to directly control the spraying process using digital information, with the spraying amount per square meter being 1400 g;

[0204] ⑿ Drying of the decorative wear-resistant layer: Dry the decorative wear-resistant layer in step ⑾, with the drying temperature being 150 °C and the drying time being 8 min;

[0205] ⒀ High-temperature firing: Send the ceramic green body in step ⑿ into a roller hearth kiln for firing;

[0206] For the high-temperature firing, the firing temperature is 1220 °C, the firing time is 75 minutes, the water absorption rate of the fired product is 0.06%, and the Ra value of the product out of the kiln is 1.72 μm.

[0207] ⒁ Processing: Polish and edge-grind the fired semi-finished product to finally obtain a polished through-body wear-resistant special granite ceramic finished brick.

[0208] The processing specifically is to first polish the product obtained in step ⒀ and then edge-grind it. The polishing is the polishing of the decorative wear-resistant layer surface; the polishing process parameters are: the pressure of the polishing machine is 0.4 Mpa, the polishing speed is 20 m / min, the polishing block combination is: 12 groups of 3000-mesh elastic polishing blocks, 18 groups of 5000-mesh elastic polishing blocks, 20 groups of 6000-mesh elastic polishing blocks, 6 groups of 2000-mesh fiber polishing blocks, 8 groups of 3000-mesh fiber polishing blocks, the polishing cutting amount is 0.042 mm, and the Ra value of the product after polishing is 0.052 μm.

[0209] The difference between Comparative Example 2 and Example 1 is that the decorative wear-resistant layer formulation material is not subjected to light firing processing and is directly formulated and used according to the green body formula.

[0210] Specifically, the all-through wear-resistant special granite ceramic tiles were prepared by using the methods of Example 1 and Comparative Example 2 respectively. The obtained ceramic tiles were tested for wear quality at 12,000 revolutions or flexural strength, water absorption, and Mohs hardness performance according to the testing methods of the national standard for ceramic tiles GB / T 4100-2015. The results are shown in Table 2 below:

[0211] Table 2 Example 1 and Comparative Example 2

[0212]

[0213] From the test results of Example 1 and Comparative Example 2, it can be seen that when the decorative wear-resistant layer formula material in the present invention is not subjected to light calcination processing, the wear resistance, Mohs hardness, and flexural strength of the prepared ceramic tiles will all decrease. From Figure 1 and Figure 3 the phase detection results, it can be seen that Figure 1 the types and contents of crystal phases of Figure 3 are higher than those of

[0214] Example 2

[0215] The all-through wear-resistant special granite ceramic tile with porphyritic effect described in this example mainly includes two parts: a wear-resistant body layer and a decorative wear-resistant layer. The main production process technical route is as follows:

[0216] ⑴ Preparation of polycrystalline phase wear-resistant matrix body formula slurry: The raw materials in the body formula are proportioned and ball-milled to obtain polycrystalline phase wear-resistant body formula slurry, which is then sent to the transfer slurry tank for storage and aging for later use;

[0217] The polycrystalline phase wear-resistant body formula consists of the following raw material components by weight: ball clay 9.55%, high-white kaolin 10%, mixed mud 12%, calcined talc 4%, bentonite 4%, potassium-sodium stone powder 19%, finely ground lithium tailings 10%, calcined bauxite 5%, fine corundum powder 20%, ultrafine zirconium silicate 3%, high-purity anatase titanium dioxide powder 2%, body strengthening agent 0.35%, and deflocculant 1.1%;

[0218] The formula of the polycrystalline wear-resistant green body consists of the following chemical components by weight percentage: Al2O3 37.52 wt%, SiO2 49.27 wt%, K2O 1.54 wt%, Fe2O3 0.66 wt%, Na2O 1.65 wt%, CaO 0.21 wt%, MgO 1.10 wt%, TiO2 1.98 wt%, ZrO2 1.93 wt%, loss on ignition 4.14 wt%.

[0219] The processing of the formula of the polycrystalline wear-resistant green body adopts a wet ball milling process, and the median diameter D50 of its slurry is 9.7 μm.

[0220] The fine corundum powder is α-Al2O3 with an Al2O3 content of 99.4%, an Fe2O3 content of 0.6%, and a particle size D50 of 1.86 μm.

[0221] The chemical composition of the finely ground lithium tailings consists of Al2O3 17.83 wt%, SiO2 69.11 wt%, K2O 3.50 wt%, Fe2O3 0.68 wt%, Na2O 3.45 wt%, CaO 0.84 wt%, MgO 0.42 wt%, Li2O 0.41 wt%, trace elements 0.18 wt%, loss on ignition 3.58 wt%. The trace elements include special elements such as rubidium, gallium, strontium, cadmium, nickel, etc.; the particle size D50 of the finely ground lithium tailings is 5.4 μm.

[0222] The ZrO2 content of the ultrafine zirconium silicate is 64.8%, and the particle size D50 is 0.82 μm.

[0223] The high-purity anatase titanium dioxide powder is TiO2, anatase titanium white powder with a content of 98.6%, the whiteness value of the powder is 97.2%, the volatile matter at 105° is 0.3%, the sieve residue on a 325-mesh sieve is 0.01%, and the particle size D50 is 0.93 μm.

[0224] ⑵ Preparation of the slurry for the high-transparency porphyritic green body formula: The raw materials in the green body formula are proportionally batching and ball milled, and after obtaining the slurry for the high-transparency porphyritic green body formula, it is sent to the transfer slurry tank for storage and aging for later use.

[0225] The high-transparency porphyritic green body formula consists of the following raw material components by weight percentage: ultra-white ball clay 12%, ultra-white kaolin 12%, ultra-white calcined talc 3%, high-white bentonite 4%, high-white potassium-sodium feldspar 20%, glass powder 15%, ultra-white lithium tailings powder 17.3%, barium carbonate 15%, green body strengthening agent 0.6%, deflocculant 1.1%.

[0226] The formula of the high-transparency porphyritic body blank is composed of the following chemical components by weight: Al2O3 16.12 wt%, SiO2 57.82 wt%, K2O 1.78 wt%, Fe2O3 0.14 wt%, Na2O 3.97 wt%, CaO 0.25 wt%, MgO 1.25 wt%, BaO 11.69 wt%, loss on ignition 6.98 wt%;

[0227] The whiteness of the formula of the high-transparency porphyritic body blank is 76%, the light transmittance is controlled at 16.3%, and the wet ball milling process is used for processing the formula of the high-transparency porphyritic body blank, and the median diameter D50 of the slurry is 9.3 μm.

[0228] The ball clay, high-white kaolin, calcined talc, bentonite, potassium-sodium stone powder, and finely ground lithium tailings are subjected to the iron removal process three times to obtain super-white ball clay with a whiteness of 72%; super-white kaolin with a whiteness of 74%; calcined talc with a whiteness of 77%; super-white bentonite with a whiteness of 73%; super-white potassium-sodium stone powder with a whiteness of 79%; and super-white lithium tailings powder with a whiteness of 81%;

[0229] ⑶ Preparation of different color powders: According to the requirements of the texture pattern design, a certain proportion of ceramic colorants or opacifiers are added to the slurries of the polycrystalline phase wear-resistant body blank formula in step ⑴ and the high-transparency porphyritic body blank formula in step ⑵, and after being stirred evenly, they are sent to a spray drying tower for powder making to obtain color powders and stored for aging for later use;

[0230] Eight kinds of color powders are set, and the specific settings are as follows:

[0231] The white color powder is composed of the following components by weight percentage: 90 wt% of the slurry of the polycrystalline phase wear-resistant body blank formula, and 10 wt% of the opacifier; among which the opacifier is composed of the following components by weight percentage: 20 wt% of zirconia, 55 wt% of zirconium silicate, and 25 wt% of titanium dioxide;

[0232] The light apricot color powder is composed of the following components by weight percentage: 100 wt% of the slurry of the high-transparency porphyritic body blank formula;

[0233] The gray color powder is composed of the following components by weight percentage: 99.7 wt% of the slurry of the polycrystalline phase wear-resistant body blank formula, 0.2 wt% of cobalt black colorant, and 0.1 wt% of orange colorant;

[0234] The light green color powder is composed of the following components by weight percentage: 99.8 wt% of the slurry of the high-transparency porphyritic body blank formula, 0.18 wt% of apple green colorant, and 0.02 wt% of chromium green colorant;

[0235] The black color powder is composed of the following components by weight percentage: 98.8 wt% of the slurry of the polycrystalline phase wear-resistant body blank formula, 1.1 wt% of cobalt black colorant, and 0.1 wt% of manganese red colorant;

[0236] The brown color powder consists of the following components by weight percentage: 97.3 wt% of the polycrystalline phase wear-resistant green body formula slurry, 0.4 wt% of cobalt black pigment, 0.7 wt% of praseodymium yellow pigment, and 1.6 wt% of manganese red pigment;

[0237] The light yellow color powder consists of the following components by weight percentage: 99.4 wt% of the high-transparency porphyry green body formula slurry, 0.4 wt% of orange pigment, and 0.2 wt% of praseodymium yellow pigment;

[0238] The red color powder consists of the following components by weight percentage: 98.4 wt% of the polycrystalline phase wear-resistant green body formula slurry, 1.3 wt% of manganese red pigment, and 0.3 wt% of praseodymium yellow pigment;

[0239] The spray drying tower adopts a pressure type spray drying system. The above pressure type spray drying system uses a nozzle plate with a pore diameter of 1.8 mm, an atomization pressure of 2.2 MPa, and the particle size distribution of the obtained powder is as follows: the proportion of particles larger than 20 mesh is 2.5%, the proportion of particles between 20 mesh and 40 mesh is 23.4%, the proportion of particles between 40 mesh and 60 mesh is 41.9%, the proportion of particles between 60 mesh and 80 mesh is 17.2%, the proportion of particles smaller than 80 mesh is 0.85%, and the powder specific gravity is 0.92 g / cm 3 , the moisture content is controlled at 6.5%, and the angle of repose is controlled at 35°;

[0240] ⑷ Preparation of different color granular materials: A part of the color powder in step ⑶ is granulated by a granulating device to obtain different color granular materials;

[0241] There are 5 types of the color granular materials, specifically white granules, black granules, brown granules, light apricot granules, and light yellow granules;

[0242] The granulating device includes 5 parts: a discharging device, a leveling device, a pressing roller, a cutting knife, and a conveying belt. It can prepare granules with various effects, colors, thicknesses, and specifications, and is composed of several discharging devices arranged above the conveying belt, a leveling device, a pressing roller, and a cutting knife arranged along the running direction of the conveying belt behind the discharging device. The discharging device spreads a total of 5 different color powders, namely white color powder, black color powder, brown color powder, light apricot color powder, and light yellow color powder in step ⑶ on the surface of the conveying flat belt in multiple layers according to design parameters. After being leveled to a fixed height by the leveling device according to the particle thickness requirement, it is pressed into a block by the pressing roller, and finally transported to the cutting knife to be processed into color granular materials of different colors, sizes, and shapes for storage and standby.

[0243] The size of the color granular material is 3 - 10 mm: the thickness is 5 mm, the flexural strength is 0.12 Mpa, and the bulk density is 1.61 g / cm 3 .

[0244] ⑸ Preparation of mixed powder: Mix the color powder in step ⑶ and the color granular material in step ⑷ evenly according to the designed ratio to obtain the mixed powder for standby;

[0245] Four types of the mixed powder are set according to the design requirements. Specifically,

[0246] The A mixed powder is composed of the following components by weight percentage: 10wt% of white granules, 5wt% of black granules, 30wt% of light apricot color powder, and 55wt% of gray color powder;

[0247] The B mixed powder is composed of the following components by weight percentage: 8wt% of brown granules, 15wt% of light yellow granules, 5wt% of white granules, 3wt% of black color powder, and 69wt% of gray color powder;

[0248] The C mixed powder is composed of the following components by weight percentage: 5wt% of brown granules, 20wt% of light apricot granules, 10wt% of white granules, 15wt% of red color powder, 40wt% of gray color powder, and 10wt% of light green color powder;

[0249] The D mixed powder is composed of the following components by weight percentage: 15wt% of light yellow color powder, 35wt% of light apricot color powder, 3wt% of black color powder, and 47wt% of gray color powder.

[0250] ⑹ Through-body cloth laying: Lay the mixed powder in step ⑸ through the through-body cloth laying forming system according to the design parameters to obtain a blank layer with porphyritic granite texture;

[0251] Please refer to Figure 6 As shown, the through-body cloth laying forming system includes a through-body cloth laying platform 1, a pressing and forming platform 2, and a conveying mechanism 3; the through-body cloth laying platform consists of a cloth laying mechanism 11, a transition belt 12, a transition hopper 13, a grille 14, a transfer replenishing hopper 15, and a movable replenishing hopper 16. There are 6 groups of the cloth laying mechanism 11, which are arranged at the uppermost part of the through-body cloth laying platform 1. After the cloth laying mechanism 11 completes cloth laying according to the designed texture pattern, a blank layer is formed. The blank layer is conveyed by the transition belt 12 to the transition hopper 13, fixed by the grille 14, and then sent to the mold cavity 21 in the pressing and forming platform 2 arranged at the tail end of the through-body cloth laying platform 1 through the conveying mechanism 3. After being replenished and leveled by the movable replenishing hopper 16, it is pressed and formed to obtain a wear-resistant blank layer;

[0252] The blank layer is formed with a granite pattern texture that is consistent from bottom to top by the through-body cloth laying forming system, and its thickness can be controlled to be 80mm.

[0253] ⑺ Compression molding: Feed the blank layer in step ⑹ into the mold cavity of the molding mechanism for pressing to obtain a wear-resistant blank layer;

[0254] The pressing pressure for the compression molding is 45 MPa / cm 3 , and the wear-resistant blank layer has a thickness of 20 mm.

[0255] ⑻ Drying: Feed the formed wear-resistant blank layer into a roller hearth kiln for drying, and control the strength of the fired porcelain blank to 2.2 Mpa;

[0256] The drying time is 110 minutes; the residual moisture content of the green body after drying is 0.42%;

[0257] ⑼ Spraying water: Spray water on the surface of the wear-resistant blank in step ⑻ for wetting;

[0258] ⑽ Preparation of color slurry: Based on the polycrystalline wear-resistant matrix blank formula in step ⑴ and the high-transparency spotted crystal blank formula in step ⑵, introduce ceramic colorants, pigments and raw materials such as kaolin, and obtain color slurry through processing techniques such as calcination, grinding, and spray drying;

[0259] The color slurry is ground into slurry using a wet ball milling process, with a specific gravity of 1.75 g / cm 3 , a viscosity of 60 mPa·s at 40°, and the D50 particle size is controlled to 12 μm;

[0260] Eight types of color slurries are set according to design requirements, specifically including:

[0261] Color slurry 1 is composed of the following components by weight percentage: 99 wt% of wear-resistant base slurry and 1 wt% of cobalt blue colorant;

[0262] Color slurry 2 is composed of the following components by weight percentage: 97 wt% of wear-resistant base slurry and 3 wt% of vanadium zirconium blue colorant;

[0263] Color slurry 3 is composed of the following components by weight percentage: 98 wt% of wear-resistant base slurry and 2 wt% of brown colorant;

[0264] Color slurry 4 is composed of the following components by weight percentage: 98 wt% of high-transparency base slurry and 2 wt% of encapsulated red colorant;

[0265] Color slurry 5 is composed of the following components by weight percentage: 97 wt% of wear-resistant base slurry and 3 wt% of orange colorant;

[0266] Color slurry 6 is composed of the following components by weight percentage: 97 wt% of high-transparency base slurry and 3 wt% of encapsulated yellow colorant;

[0267] The color slurry 7 is composed of the following components by weight percentage: wear-resistant base slurry 99wt%, black pigment 1wt%;

[0268] The color slurry 8 is composed of the following components by weight percentage: high-transparency slurry 98wt%, green pigment 2wt%;

[0269] The wear-resistant base slurry is composed of the following components by weight percentage: lightly burned wear-resistant material 89.2%, kaolin 9.52%, CMC 0.32%, melamine 0.56%, defoaming agent 0.4%;

[0270] The formula composition of the lightly burned wear-resistant material is the same as that of the polycrystalline wear-resistant green body in step (1), except that it needs to be lightly burned. The lightly burning process is as follows: after the formula is prepared by weight percentage, it is ball-milled into slurry according to the wet process, the slurry moisture is 36%, the viscosity at 40° is 60 mPa·s, and the D50 particle size is 4 μm; the ball-milled slurry is spray-dried to obtain powder, and the obtained powder is filled into a sagger made of refractory material and fired at a temperature of 1080°C to obtain the lightly burned wear-resistant material;

[0271] The high-transparency base slurry is composed of the following components by weight percentage: lightly burned high-transparency material 89.2%, kaolin 9.52%, CMC 0.32%, melamine 0.56%, defoaming agent 0.4%;

[0272] The formula composition of the lightly burned high-transparency material is the same as that of the high-transparency porphyritic green body in step (2), except that it needs to be lightly burned. The lightly burning process is as follows: after the formula is prepared by weight percentage, it is ball-milled into slurry according to the wet process, the slurry moisture is 36%, the viscosity at 40° is 60 mPa·s, and the D50 particle size is 4 μm; the ball-milled slurry is spray-dried to obtain powder, and the obtained powder is filled into a sagger made of refractory material and fired at a temperature of 1050°C to obtain the lightly burned high-transparency material.

[0273] (11) Spray slurry decoration: On the surface of the wetted green body, use the color slurry in step (10) for digital spray slurry process decoration according to the designed pattern to form a decorative wear-resistant layer;

[0274] The decorative wear-resistant layer is formed by decorative spraying with 8 different color slurries according to the designed pattern texture using the numerical control spray slurry process. The digital spray slurry pattern is similar to the pattern texture of the wear-resistant green body layer, the pattern is narrowed by 0.2 mm, and the thickness of the decorative wear-resistant layer is 0.8 mm.

[0275] The digital spray slurry process is a process that directly controls spraying using digital information, and the spraying amount per square meter is 1400 g.

[0276] (12) Drying of the decorative wear-resistant layer: Dry the decorative wear-resistant layer in step (11), the drying temperature is 150°C, and the drying time is 8 min;

[0277] ⒀ High-temperature firing: Feed the ceramic green body from step ⑿ into a roller hearth kiln for firing.

[0278] For the said high-temperature firing, the firing temperature is 1220 °C, the firing time is 75 minutes, the water absorption rate of the product after firing is 0.06%, and the Ra value of the product out of the kiln is 1.72 μm.

[0279] ⒁ Processing: Grind the edges of the fired semi-finished product to finally obtain a natural-surface all-body wear-resistant special granite ceramic finished brick.

[0280] Prepare all-body wear-resistant special granite ceramic bricks by the method of Embodiment 2, and conduct tests on the obtained ceramic bricks and natural granite for the wear depth of unglazed bricks, flexural strength, water absorption rate, and Mohs hardness performance according to the national standard test method or the conventional test method of ceramic bricks. The results are shown in Table 3 below:

[0281] Table 3 Embodiment 2 and natural granite

[0282]

[0283] From the test results of Embodiment 2 and natural granite, it can be seen that the wear resistance, Mohs hardness, and flexural strength of the granite ceramic bricks prepared by the method of Embodiment 2 are better than those of natural granite. This is because when preparing granite ceramic bricks by the method of Embodiment 2, more high-hardness wear-resistant crystals are produced, including mullite, corundum, zircon, quartz, rutile, anorthite, etc. Among them, the Mohs hardness of mullite and anorthite reaches 6, that of rutile is 6 - 6.5, that of zircon is 7.5 - 8, and that of corundum is 9. These high-hardness wear-resistant crystals not only have a large variety but also a high content, thus improving the wear resistance of the product.

[0284] The above are only the preferred embodiments of the present invention. All equivalent changes and modifications made within the scope of the claims of the present invention shall fall within the scope covered by the claims of the present invention.

Claims

1. A method for preparing a wear-resistant special granite ceramic tile with phenocryst effect, characterized in that: The following steps are involved: ⑴ Preparation of polycrystalline wear-resistant matrix blank formula slurry: the raw materials in the polycrystalline wear-resistant matrix blank formula are ball-milled according to the proportion, and the polycrystalline wear-resistant blank formula slurry is sent to the transfer slurry pool for storage and aging for standby use; the polycrystalline wear-resistant blank formula is composed of the following raw material components by weight percentage: ball clay 8% to 15%, high white kaolin 8% to 15%, mixed mud 10% to 15%, burnt talc 0% to 5%, bentonite 3 to 6%, potassium sodium stone powder 15 to 25%, finely ground lithium tailings 8% to 15%, calcined bauxite 4% to 8%, fine corundum powder 15% to 25%, ultrafine zirconium silicate 0% to 5%, high purity anatase titanium dioxide powder 0% to 5%, blank reinforcement 0% to 1%, debonding agent 1 to 3%; (2) Preparation of high-transmittance porphyroblast green body formula slurry: the raw materials in the high-transmittance porphyroblast green body formula are ball-milled according to the proportion, and the high-transmittance porphyroblast green body formula slurry is sent to the transfer slurry pool for storage and aging for later use; the high-transmittance porphyroblast green body formula is composed of the following raw material components by weight percentage: ultra-white ball clay 8%-15%, ultra-white kaolin 8%-15%, ultra-white calcined talc 0%-5%, high-white bentonite 3-6%, high-white potassium sodium stone 15-25%, glass powder 10-20%, ultra-white lithium tailings powder 10%-20%, barium carbonate 10%-20%, green body reinforcing agent 0-1%, debonding agent 1-3%; ⑶ Preparation of powders of different colors: according to the requirements of the texture pattern design, add a set ratio of ceramic colorant or emulsifier to the polycrystalline wear-resistant green body formula slurry in step ⑴ and the high-transparency porphyroblast green body formula slurry in step ⑵, stir evenly and send to a spray drying tower for powdering to obtain color powder and store it for aging for later use; (4) Preparation of granular materials of different colors: Part of the color powder of step (3) is granulated by a granulating device to obtain granular materials of different colors; (5) Preparation of mixed powder: uniformly mix the color powder of step (3) and the color granular material of step (4) according to the designed ratio to obtain a mixed powder for use; (6) Whole-body fabrication: The mixed powder material in step (5) is arranged in texture according to the design parameters through the whole-body fabrication forming system to obtain a blank layer with a phenocryst granite texture; (7) Pressing and molding: feeding the blank layer of step (6) into the mold cavity of the molding mechanism for pressing to obtain a wear-resistant blank layer; ⑻ Drying: The formed wear-resistant body layer is sent to the roller kiln for drying. The strength of the dried porcelain body is controlled to be 1.5-2.5Mpa; ⑼ Water spraying: spray water on the surface of the wear-resistant blank in step ⑻ to wet it; ⑽Preparation of color slurry: Based on the formula of the polycrystalline wear-resistant matrix body in step ⑴ and the formula of the high-transparency porphyroblast body in step ⑵, ceramic colorant and kaolin are introduced, and the color slurry is obtained through calcination, grinding and spray drying. ⑾Spraying decoration: on the wetted surface of the blank, use the color slurry in step ⑽ to perform digital spraying decoration according to the designed pattern to form a decorative wear-resistant layer; ⑿ Drying of decorative wear-resistant layer: drying temperature is 100-200℃, drying time is 3-8min; ⒀High temperature firing: sending the ceramic body of step ⑿ into a roller kiln for firing; ⒁Processing: The fired semi-finished products are polished or not polished and ground, and finally the wear-resistant special granite ceramic finished tiles with polished, natural or special-shaped surfaces are obtained.

2. The method for preparing the wear-resistant special granite ceramic tile with phenocryst effect according to claim 1, characterized in that: The multi-crystalline wear-resistant blank in step (1) is composed of the following chemical components by weight percentage: Al2O3 30-40wt%, SiO2 45-55wt%, K2O 1-3wt%, Fe2O3 1-2wt%, Na2O 1-3wt%, CaO 0-0.5wt%, MgO0.5-2.5wt%, and ignition loss 0-5wt%; In the step (1), the processing of the polycrystalline wear-resistant blank formulation adopts a wet ball milling process, and the median diameter D50 of the slurry is controlled to be 8.5-10.5 μm.

3. The method for preparing the wear-resistant special granite ceramic tile with phenocryst effect according to claim 2, characterized in that: The fine corundum powder is α-Al2O3 with an Al2O3 content of 99-100%, a Fe2O3 content of 0-1%, and a particle size D50 <3μm; The chemical composition of the finely ground lithium tailings is composed of the following components by weight percentage: Al2O3 15-20 wt%, SiO2 65-75 wt%, K2O 2-5 wt%, Fe2O3 0-4 wt%, Na2O 2-5 wt%, CaO 0-2 wt%, MgO 0-1 wt%, Li2O 0.3-1 wt%, trace elements 0-1 wt%, and ignition loss 0-5 wt%; the particle size D50 of the finely ground lithium tailings is between 4 μm and 8 μm; the trace elements include rubidium, gallium, strontium, cadmium, and nickel; The ultrafine zirconium silicate has a ZrO2 content greater than 64% and a particle size D50 less than 1 μm.

4. The method for preparing the wear-resistant special granite ceramic tile with phenocryst effect according to claim 1, characterized in that: The formula of the high-transparency phenocryst blank in step (2) is composed of the following chemical components by weight percentage: Al2O3 15~20wt%, SiO2 60~70wt%, K2O 1~3wt%, Fe2O3 0~0.5 wt%, Na2O 1~3wt%, CaO0~0.5wt%, MgO 0.5~2.5wt%, BaO 7~16wt%, ignition loss 0~8wt%; In step (2), the whiteness of the high-transmittance porphyroblast blank formula is controlled to be 70-80%, the transmittance is controlled to be 10-20%, the high-transmittance porphyroblast blank formula is processed by wet ball milling process, and the median diameter D50 of the slurry is controlled to be 8.5-10.5 μm; The raw materials used in the high-transparency porphyroblast body formula of step (2) are ultra-white ball clay, ultra-white kaolin, ultra-white burned talc, high-white bentonite, ultra-white lithium tailings powder, and high-white potassium sodium stone, which are obtained by removing iron from ball clay, high-white kaolin, burned talc, bentonite, potassium sodium stone powder, and finely ground lithium tailings. The raw materials are deironed 1 to 5 times, and the whiteness is controlled to be 70 to 80%.

5. The method for preparing the wear-resistant special granite ceramic tile with phenocryst effect according to claim 1, characterized in that: The ceramic colorant in step (3) is selected from the following: The following components are included in percentage by weight Composition: cobalt blue: 0~100wt%, manganese red: 0~100wt%, apple green: 0~100wt%, chrome green: 0~100wt%, orange: 0~100wt%, praseodymium yellow: 0~100wt%, cobalt black: 0~100wt%; The following components are included in percentage by weight Composition: cobalt blue: 0~100wt%, vanadium zirconium blue: 0~100wt%, brown: 0~100wt%, package red: 0~100wt%, orange: 0~100wt%, package yellow: 0~100wt%, black: 0~100wt%, green: 0~100wt%; The opacifier in step (3) is composed of the following components by weight percentage: zirconium dioxide: 0-100wt%, zirconium silicate: 0-100wt%, titanium dioxide: 0-100wt%; Step (3) The spray drying tower adopts a pressure spray drying system, the spray drying system uses a nozzle sheet combination with an aperture of 1.5 mm to 2.0 mm, and the atomization pressure is 1.8 MPa to 2.6 MPa. The particle grading of the obtained powder is that the particles on the 20 mesh sieve account for less than 6%, the particles between 20 mesh and 40 mesh account for 20% to 25%, the particles between 40 mesh and 60 mesh account for 40% to 45%, the particles between 60 mesh and 80 mesh account for 15% to 20%, and the particles below 80 mesh account for less than 3%. The specific gravity of the powder is 0.85 to 0.95 g / cm³, the moisture content is controlled to be 6 to 8%, and the angle of repose is controlled to be 33º to 38º.

6. The method for preparing the wear-resistant special granite ceramic tile with phenocryst effect according to claim 1, characterized in that: The granulation equipment in step (4) includes a discharging device, a scraping device, a pressure roller, a cutter and a conveyor belt, and is composed of a plurality of discharging devices arranged above the conveyor belt, and a scraping device, a pressure roller and a cutter respectively arranged behind the discharging device along the running direction of the conveyor belt; the discharging device spreads the color powder in step (3) on the surface of the conveyor belt in multiple layers according to the design parameters, and is scraped and flattened by the scraping device at a fixed height according to the particle thickness requirement, and then pressed into a block by a pressure roller, and finally transported to the cutter to be processed into color granular materials of different colors, sizes and shapes for storage and standby; the color granular materials are provided with 2 to 6 kinds, and the particle size is controlled to be 3 to 20 mm: the thickness is controlled to be 1 to 10 mm, the flexural strength is controlled to be ≥0.1 Mpa, and the volume density is controlled to be ≥1.0 g / cm³; the mixed powder in step (5) is provided with 2 to 6 kinds, and is composed of the following components by weight percentage: color powder: 0 to 100 wt%, color granular material: 0 to 100 wt%.

7. The method for preparing the wear-resistant special granite ceramic tile with phenocryst effect according to claim 1, characterized in that: Step (6) The blank layer is formed by a whole-body fabric forming system with a consistent granite pattern texture from bottom to top, and the whole-body fabric forming system includes a whole-body fabric platform, a pressing and forming platform, and a conveying mechanism; the whole-body fabric platform is composed of a fabric mechanism, a transition belt arranged at the bottom of the fabric mechanism, a transition hopper arranged at a position where the transition belt travels at a terminal lower than the transition belt, a grid connected to the bottom of the transition hopper, a movable feeding hopper arranged longitudinally above the conveying mechanism on the side of the pressing and forming platform, and a transfer feeding hopper; the fabric mechanism is designed in multiple groups and arranged at the top of the whole-body fabric platform; The material distribution mechanism forms a blank layer after the material distribution is completed according to the designed texture pattern. The blank layer is transferred to the transition hopper by the transition belt, and is fixed by the grid and then sent to the mold cavity in the pressing and forming platform arranged at the tail end of the whole material distribution platform through the conveying mechanism. The material is fed by the movable feeding hopper and scraped flat, and then pressed and formed to obtain a wear-resistant blank layer. In step (6), the blank layer is formed by a whole-body fabric forming system to form a granite pattern texture that is consistent from bottom to top, and its thickness is controlled to be 18 mm to 80 mm.

8. The method for preparing the wear-resistant special granite ceramic tile with phenocryst effect according to claim 1, characterized in that: In step (7), the pressing pressure is > 40 MPa / cm 2 , the thickness of the wear-resistant green body layer is controlled to be 9mm-40mm; the drying time in step ⑻ is 50-120 minutes; the residual moisture of the green body after drying is ≤0.5%; the color slurry in step ⑽ is composed of the following components by weight percentage: 95-100% of the base slurry, 0-5% of the ceramic colorant, which are prepared by weight percentage and ground into slurry using a wet ball milling process; the specific gravity of the color slurry is controlled to be 1.75±0.5 g / cm³, and the D50 particle size is controlled to be 10μm-15μm; The basic slurry is composed of the following components by weight percentage: light-burned wear-resistant material: 0-90wt%, light-burned high-permeability material: 0-90wt%, kaolin: 8-20wt%, CMC: 0.2-1.0wt%, trimer: 0.5-1.0wt%, defoamer: 0.2-1.0wt%; The formula compositions of the lightly fired wear-resistant material and the lightly fired high-permeability material are respectively consistent with the formula of the polycrystalline wear-resistant blank in step (1) and the formula of the high-permeability porphyroblast blank in step (2), except that light firing processing is required; the light firing processing is to prepare the formula according to weight percentage, and then ball-mill it into slurry according to a wet process, the slurry has a moisture content of 35-40%, and a D50 particle size of 3μm-6μm; the ball-milled slurry is spray-dried to obtain a powder, and the obtained powder is loaded into a sagger made of refractory material or spread on a flat plate made of refractory material, and fired at a temperature of 1050-1150°C to obtain the lightly fired wear-resistant material and the lightly fired high-permeability material.

9. The method for preparing the wear-resistant special granite ceramic tile with phenocryst effect according to claim 1, characterized in that: Step ⑾ The decorative wear-resistant layer is formed by CNC spraying process, using a variety of different color slurries for decorative printing according to the designed pattern texture. The digital spraying pattern is similar to the pattern texture of the wear-resistant blank layer, and the pattern is narrowed by 0.2mm to 0.4mm; The digital spraying process in step ⑾ is a process of directly controlling the printing by using digital information, and can realize the printing of 4 to 10 different color slurries at the same time; The high temperature firing described in step (9) has a firing temperature of 1180-1250°C and a firing time of 60-120 minutes. The water absorption rate of the fired product is ≤0.5%, and the Ra value of the product out of the kiln refers to the arithmetic mean deviation of the profile, that is, the surface roughness is between 1.5 and 3 μm; The processing in step ⒁ includes two situations. The first situation is to directly grind the edge of the product after sintering in step ⒀; the second situation is to first polish the product obtained in step ⒀ and then grind the edge; The polishing is the polishing of the wear-resistant surface: the polishing process parameters are: the polishing machine pressure is below 0.6Mpa, the polishing speed is 15-30m / min, the polishing abrasive blocks are 10-15 groups of 3000 mesh elastic abrasive blocks, 15-20 groups of 5000 mesh elastic abrasive blocks, 15-25 groups of 6000 mesh elastic abrasive blocks, 5-10 groups of 2000 mesh fiber abrasive blocks, 5-10 groups of 3000 mesh fiber abrasive blocks, the polishing cutting amount is less than 0.05mm, and the Ra value of the product after polishing is ≦0.1μm.

10. A wear-resistant special granite ceramic tile with phenocryst effect throughout the body, prepared by the preparation method according to any one of claims 1 to 9.

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