Three-dimensional embossed ceramic tile and preparation method thereof

Abstract

The invention discloses a three-dimensional embossment type ceramic tile and a preparation method thereof, the three-dimensional embossment type ceramic tile sequentially comprises a base layer, a ground coat layer, a three-dimensional layer, a glaze layer and a polishing layer from bottom to top, the base layer is located at the bottom layer of the ceramic tile and has a thickness of 8-10mm, the ground coat layer is formed by applying ground coat on the base layer and has a thickness of 0.5-1mm, and the three-dimensional layer is located at the bottom layer of the ceramic tile and has a thickness of 0.5-1mm. The three-dimensional layer is a pattern layer formed after ink-jet printing is carried out on the ground glaze layer, the thickness of the pattern layer is 1.5-2.5 mm, the glaze surface layer is formed after overglaze is applied to the three-dimensional layer, the thickness of the glaze surface layer is 0.4-0.8 mm, and the polishing layer is formed after polishing treatment is carried out on the glaze surface layer. According to the three-dimensional embossment type ceramic tile, the ultra-white ground glaze, the multi-layer ink-jet printing three-dimensional layer and the cover glaze layer are combined by adopting multi-layer laminated glaze, so that the three-dimensional embossment type ceramic tile can clearly embody the texture and texture of raw stone, has better visual impact force and artistic expressive force, and improves the three-dimensional effect and artistic ornamental value of the ceramic tile; the requirements of the market on high-end decorative ceramic tiles are met.

Description

Technical Field

[0001] The invention relates to the technical field of ceramic tiles, and in particular to a three-dimensional relief ceramic tile and a preparation method thereof. Background Art

[0002] With the improvement of people's living standards, the requirements for decoration are getting higher and higher. As a common building material, the appearance and texture of ceramic tiles directly affect the decorative effect. Traditional ceramic tiles are mostly flat, lacking three-dimensional sense and artistry, and it is difficult to meet the pursuit of personalization and artistry of modern consumers. Consumers not only need ceramic tiles to have basic decorative and practical functions, but also hope that ceramic tiles can show unique artistic charm and individual expression. Especially in the high-end market, consumers have higher expectations for the texture and visual effects of tiles. They are more inclined to choose products that can provide natural stone texture and three-dimensional effect. In this context, three-dimensional relief ceramic tiles came into being, which are favored for their unique three-dimensional sense and realistic decorative effect. This kind of ceramic tile can not only increase the sense of hierarchy and art of space, but also create a unique decorative atmosphere through different relief patterns and textures. However, in the existing technology, most of the ceramic tiles that achieve three-dimensional relief effect have a relatively single texture, the relief pattern is not clear enough, and cannot reflect the natural effect of the concave and convex texture of the original stone, lacking the texture and hierarchy of the original stone. Therefore, it is necessary to develop a ceramic tile with clear patterns that can reflect the texture and feel of the original stone to meet the market demand for high-quality decorative products. Summary of the invention

[0003] The purpose of the present invention is to provide a three-dimensional relief ceramic tile and a preparation method thereof. By combining an ultra-white base glaze, a multi-layer inkjet-printed three-dimensional layer, and a surface glaze layer using a multi-layer stacked glaze, the three-dimensional relief ceramic tile can clearly reflect the texture and feel of the original stone, thereby enhancing the three-dimensional effect and artistic appreciation of the ceramic tile.

[0004] To achieve the above object, the present invention provides the following technical solutions: A three-dimensional relief ceramic tile comprises, from bottom to top, a base layer, a base glaze layer, a three-dimensional layer, a glaze layer and a polishing layer, wherein the base layer is located at the bottom layer of the ceramic tile and has a thickness of 8-10 mm, the base glaze layer is formed after applying a base glaze on the base layer and has a thickness of 0.5-1 mm, the three-dimensional layer is a pattern layer formed after inkjet printing on the base glaze layer and has a thickness of 1.5-2.5 mm, the glaze layer is formed after applying a top glaze on the three-dimensional layer and has a thickness of 0.4-0.8 mm, and the polishing layer is formed after polishing the glaze layer.

[0005] Furthermore, the base glaze comprises the following raw materials in parts by weight: 20-25 parts of potassium feldspar, 8-10 parts of spodumene, 15-18 parts of kaolin, 10-12 parts of quartz powder, 16-20 parts of zircon sand, 2-4 parts of calcium carbonate, 4-6 parts of calcined dolomite, 2-4 parts of tricalcium phosphate, and 12-16 parts of ultra-white frit.

[0006] Furthermore, the chemical composition of the ultra-white frit is as follows: SiO2: 48-52%, Al2O3: 10-13%, ZrO2: 12-15%, MgO: 8-12%, Li2O: 1-3%, Na2O: 0-1%, ZnO: 8-10%, BaO: 2-4%, TiO2: 4-6%.

[0007] Furthermore, the glaze comprises the following raw materials in parts by weight: 20-25 parts of potassium feldspar, 10-12 parts of kaolin, 10-12 parts of quartz powder, 18-22 parts of strontium carbonate, 10-15 parts of sodium silicate, 3-5 parts of calcium carbonate, 2-4 parts of tricalcium phosphate, 0.1-0.3 parts of alkyl sulfate, 0.1-0.3 parts of polyoxyethylene fatty alcohol ether, and 20-25 parts of transparent frit.

[0008] Furthermore, the chemical composition of the transparent frit is as follows: SiO2: 50-55%, Al2O3: 10-12%, CaO: 5-8%, MgO: 2-5%, K2O: 2-5%, Na2O: 2-5%, B2O3: 6-8%, SrO: 8-10%, ZnO: 5-8%, Li2O: 1-3%, CaF2: 0.5-1%, SnO2: 1-3%.

[0009] The method for preparing a three-dimensional relief ceramic tile comprises the following steps: S1: Obtaining the base layer of ceramic tiles through batching, ball milling, sieving, spray granulation, aging, molding, drying, and sintering; S2: According to the raw material composition of the base glaze and the top glaze, the ingredients are separately mixed, ball-milled, and sieved to obtain the base glaze slurry and the top glaze slurry; S3: applying a base glaze slurry on the base layer obtained in step S1, and drying it at 40-50° C. for 30-40 minutes and then at 60-70° C. for 20-30 minutes in a gradient drying manner to form a base glaze layer after drying; S4: preheating the bottom glaze layer, controlling the temperature at 60-70°C, printing a decorative pattern on the bottom glaze layer by multi-layer inkjet printing, and sending the layer into a drying furnace for drying at 110-115°C for 80-90 minutes to form a three-dimensional layer; S5: Applying the glaze slurry on the three-dimensional layer by multi-layer stacking glaze, putting it into the kiln after drying, controlling the heating rate to be 5-10℃ / min, first firing at a low temperature of 780-800℃ for 2-3 hours, and then firing at a high temperature of 1200-1220℃ for 6-8 hours to form a glaze layer; S6: Polishing the semi-finished product obtained in step S5 to form a polishing layer, thereby obtaining a three-dimensional relief ceramic tile.

[0010] Furthermore, the multi-layer inkjet printing in step S4 is to first print a thin base pattern layer on the base glaze layer with a thickness of about 0.5-1 mm, and then print the second and subsequent layers after low-temperature drying until the set thickness of the three-dimensional layer is reached. After each printing, it is dried at 60-80°C for 15-30 minutes.

[0011] Furthermore, the multi-layer glazing in step S5 is layered glazing on the three-dimensional layer, the total number of glazing layers is controlled between 3-5 layers, the thickness of each glazing is controlled between 0.1-0.2 mm, and each glazing is dried at 60-80° C. for 20-25 minutes.

[0012] Compared with the prior art, the present invention has the following beneficial effects: The present invention combines ultra-white base glaze, multi-layer inkjet-printed three-dimensional layer, and surface glaze layer with multi-layer stacked glaze, so that the three-dimensional relief ceramic tiles can clearly reflect the texture and feel of the original stone, have better visual impact and artistic expression, enhance the three-dimensional effect and artistic appreciation of the ceramic tiles, and meet the market demand for high-end decorative ceramic tiles.

[0013] 1. The base glaze formula used in the present invention contains ultra-white frit, which provides an ultra-white base layer, laying a good foundation for the subsequent presentation of three-dimensional relief effects. This ultra-white base glaze can better simulate the pure background color of natural stone, making the three-dimensional relief pattern clearer, brighter and more vivid.

[0014] 2. The present invention can accurately reproduce the details and texture of the original stone on the base glaze layer through multi-layer inkjet printing, perfectly presenting the texture of the original stone, making the decorative effect of the ceramic tile closer to natural stone, and enhancing the decorative value and market competitiveness of the product.

[0015] 3. The present invention can form a uniform, smooth and three-dimensional glaze layer through a multi-layer glazing process, and make the glaze surface more moist, greatly improving the decorative effect and user experience of the ceramic tile. DETAILED DESCRIPTION

[0016] In order to make the technical problems, technical solutions and beneficial effects solved by the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0017] A three-dimensional relief ceramic tile comprises, from bottom to top, a base layer, a base glaze layer, a three-dimensional layer, a glaze layer and a polishing layer. The base layer is located at the bottom layer of the ceramic tile and has a thickness of 8-10 mm. The base glaze layer is formed by applying a base glaze on the base layer and has a thickness of 0.5-1 mm. The three-dimensional layer is a pattern layer formed by inkjet printing on the base glaze layer and has a thickness of 1.5-2.5 mm. The glaze layer is formed by applying a top glaze on the three-dimensional layer and has a thickness of 0.4-0.8 mm. The polishing layer is formed by polishing the glaze layer.

[0018] The base glaze comprises the following raw materials in parts by weight: 20-25 parts of potassium feldspar, 8-10 parts of spodumene, 15-18 parts of kaolin, 10-12 parts of quartz powder, 16-20 parts of zircon sand, 2-4 parts of calcium carbonate, 4-6 parts of calcined dolomite, 2-4 parts of tricalcium phosphate, and 12-16 parts of ultra-white frit.

[0019] As a network former, potassium feldspar helps to form the network structure of the glaze, enhance the mechanical strength and chemical stability of the glaze, provide flux at high temperature, reduce the melting temperature of the glaze, and make it easier for the glaze to form a uniform glassy substance during the firing process. Its 20-25% ratio can ensure sufficient fluxing effect, and will not affect the chemical stability and other properties of the glaze due to excessive content. As an auxiliary flux, spodumene can improve the whiteness of the glaze, while enhancing the mechanical strength and thermal stability of the glaze and preventing the glaze from cracking. Its 8-10% ratio can ensure synergy with other raw materials such as potassium feldspar to further optimize the firing performance of the base glaze. As a binder and filler of the glaze, kaolin can improve the plasticity and formability of the glaze, help the formation of the glaze layer and the combination with the base layer, and can also improve the whiteness and covering power of the glaze surface. At the same time, it helps to adjust the expansion coefficient of the glaze. Its 15-18% ratio can ensure that the glaze does not settle and stratify during the glazing process, and maintain the uniform distribution of the glaze layer. The main component of quartz powder is silicon dioxide (SiO2), which is also a network former. It works with potassium feldspar to form the skeleton of the base glaze. At the same time, it can improve the mechanical strength and wear resistance of the glaze and increase the chemical stability of the glaze. During the firing process, quartz powder can increase the melting temperature range of the glaze, help control the firing process of the glaze, and make the glaze more uniform. Its 10-12% ratio can effectively improve the hardness, wear resistance and chemical stability of the glaze without making the melting temperature too high. Zircon sand can improve the whiteness and covering power of the glaze, and at the same time enhance the chemical stability and wear resistance of the glaze, which helps to form a uniform, stable and pure white base glaze with good covering effect. Its 16-20% ratio can ensure that the zircon sand can fully play its role in improving whiteness, covering power, chemical stability and wear resistance, making the three-dimensional pattern clearer and more durable. Calcium carbonate, as a flux, decomposes during the firing process to produce calcium oxide, which can react with other ingredients to reduce the firing temperature of the base glaze, improve the fluidity of the glaze, help the uniform coating of the glaze, and improve the gloss of the base glaze. Its 2-4% ratio can help reduce the melting point of the glaze and adjust the fluidity. Calcined dolomite can improve the mechanical strength and thermal stability of the glaze, and help adjust the expansion coefficient of the glaze to ensure the matching of the glaze and the body. Its 4-6% ratio can play a role in fluxing and improving performance, and does not affect the firing temperature of the base glaze. Tricalcium phosphate can improve the bonding and wear resistance of the glaze. Its 2-4% ratio can enhance the adhesion of the glaze, making the glaze more firm and durable. Ultra-white frit provides high whiteness and glossiness of the glaze, making the glaze whiter and brighter.

[0020] The chemical composition of the ultra-white frit is as follows: SiO2: 48-52%, Al2O3: 10-13%, ZrO2: 12-15%, MgO: 8-12%, Li2O: 1-3%, Na2O: 0-1%, ZnO: 8-10%, BaO: 2-4%, TiO2: 4-6%.

[0021] SiO2 is the main network former, and its proportion of 48-52% provides the basic glass network structure for the frit, which helps to improve the stability and high temperature resistance of the glaze. Al2O3 is a flux, which can reduce the melting point of the glaze, promote the uniform distribution and combination of other components, and enhance the chemical stability of the glaze. Its proportion of 10-13% can effectively reduce the melting point of the glaze and increase the fluidity of the glaze. ZrO2 is conducive to improving the whiteness and glossiness of the base glaze, improving its covering ability of the base layer color, and at the same time enhancing the wear resistance and chemical stability of the glaze. Its proportion of 12-15% can effectively improve the optical properties of the glaze and make the glaze whiter and brighter. MgO plays the role of flux and stabilizer in the glaze, which helps to reduce the melting temperature of the glaze and improve the fluidity and uniformity of the glaze. At the same time, MgO can also enhance the glossiness and whiteness of the glaze surface and improve the overall aesthetics of the ceramic tile. Its proportion of 8-12% can effectively optimize the melting performance of the glaze and the quality of the glaze surface. Li2O has a low melting point, which can promote the melting and flow of glazes, and also help to improve the gloss and transparency of the glaze, making the glaze brighter and cleaner. Its proportion cannot be too high, otherwise it will affect the hardness of the glaze. As a flux, Na2O can reduce the melting temperature of the frit, improve its fluidity, help the uniform coating of the glaze and improve the thermal expansion performance of the glaze. At the same time, it can also improve the gloss and whiteness of the glaze. Its proportion cannot be too high, otherwise it will lead to a decrease in the chemical stability of the glaze. ZnO plays the role of a whitening agent and an emulsifier in the glaze, which can significantly improve the whiteness, gloss and opacity of the glaze. At the same time, as a stabilizer, it can also prevent the glaze from changing color at high temperatures. Its proportion of 8-10% can ensure the high whiteness and stability of the glaze. BaO can increase the refractive index of the glaze, thereby improving the glossiness of the ceramic tile. At the same time, it can also play a role in fluxing to a certain extent, which helps the melting and sintering of the frit. Its 2-4% ratio can improve the refractive index and glossiness of the base glaze without affecting other properties of the base glaze. If the ratio is too high, it will affect the chemical stability and color stability of the base glaze. TiO2, as an emulsifier, can significantly improve the whiteness, opacity and hiding power of the glaze, scatter light, make the base glaze look whiter, and cover some impurities or color unevenness in the base glaze, improve the appearance quality, and also improve the mechanical strength and chemical stability of the glaze. Its 4-6% ratio can effectively improve the hiding power and whiteness. Too high a ratio may affect the color stability of the base glaze, resulting in the base glaze color being yellowish.

[0022] The glaze comprises the following raw materials in parts by weight: 20-25 parts of potassium feldspar, 10-12 parts of kaolin, 10-12 parts of quartz powder, 18-22 parts of strontium carbonate, 10-15 parts of sodium silicate, 3-5 parts of calcium carbonate, 2-4 parts of tricalcium phosphate, 0.1-0.3 parts of alkyl sulfate, 0.1-0.3 parts of polyoxyethylene fatty alcohol ether, and 20-25 parts of transparent frit.

[0023] Potassium feldspar, kaolin, quartz powder, calcium carbonate, and tricalcium phosphate play the same role in the top glaze as in the base glaze. Strontium carbonate (SrCO3) is the main high-gloss component. Strontium carbonate decomposes to produce strontium oxide during the firing process. Strontium oxide can improve the gloss and transparency of the glaze surface, and at the same time improve the warmth of the glaze surface, which helps the top glaze to achieve high gloss, high transparency, and good warmth. Its 18-22% ratio can ensure the high brightness of the glaze surface and make the three-dimensional pattern more vivid. Sodium silicate (Na2SiO3) can improve the transparency and fluidity of the glaze surface and help form a smooth surface. Its 10-15% ratio can effectively enhance the gloss of the glaze surface. As a surfactant, alkyl sulfate can improve the stability and fluidity of glaze slurry, and at the same time help to remove impurities in glaze, keep the glaze pure and smooth, and help to improve the transparency and gloss of glaze. As a wetting agent, polyoxyethylene fatty alcohol ether can improve the wettability and adhesion of glaze. The ratio of alkyl sulfate and polyoxyethylene fatty alcohol ether should not be too high, otherwise it will affect the chemical stability of glaze. Transparent frit can improve the melting performance and fluidity of glaze, making the glaze smoother and more transparent.

[0024] The chemical composition of the transparent frit is as follows: SiO2: 50-55%, Al2O3: 10-12%, CaO: 5-8%, MgO: 2-5%, K2O: 2-5%, Na2O: 2-5%, B2O3: 6-8%, SrO: 8-10%, ZnO: 5-8%, Li2O: 1-3%, CaF2: 0.5-1%, SnO2: 1-3%.

[0025] SiO2 in the transparent frit acts as a network former, which can form a strong glassy structure and improve the durability and gloss of the glaze. Al2O3 is a flux, which can lower the melting point of the glaze, increase the fluidity of the glaze, and improve the transparency and gloss of the glaze. CaO and MgO can improve the heat resistance and stability of the glaze, and enhance the gloss of the glaze. K2O and Na2O can adjust the expansion coefficient of the glaze to match the expansion coefficient of the ceramic matrix, reduce stress and cracks, and K2O also helps to improve the hardness and wear resistance of the glaze. B2O3 can To reduce the melting temperature of the glaze and improve its fluidity, which helps to form a smooth surface and high gloss. SrO can improve the gloss and transparency of the glaze, and work synergistically with strontium carbonate to enhance the high gloss brightness of the glaze. ZnO can improve the hardness and gloss of the glaze and enhance the scratch resistance of the glaze. Li2O further reduces the melting temperature of the glaze and improves the transparency and gloss of the glaze. CaF2 can improve the fluidity of the glaze, reduce bubbles and defects, and make the glaze smoother. SnO2 can improve the gloss and transparency of the glaze and enhance the wear resistance of the glaze.

[0026] The method for preparing a three-dimensional relief ceramic tile comprises the following steps: S1: Obtaining the base layer of ceramic tiles through batching, ball milling, sieving, spray granulation, aging, molding, drying, and sintering; S2: According to the raw material composition of the base glaze and the top glaze, the ingredients are separately mixed, ball-milled, and sieved to obtain the base glaze slurry and the top glaze slurry; S3: applying a base glaze slurry on the base layer obtained in step S1, and drying it at 40-50° C. for 30-40 minutes and then at 60-70° C. for 20-30 minutes in a gradient drying manner to form a base glaze layer after drying; Gradient drying can fully remove moisture and air from the glaze layer, allowing the moisture in the bottom glaze layer to evaporate slowly and evenly, avoiding cracks in the bottom glaze layer caused by drying stress, improving the quality of the glaze layer, and reducing defects during the firing process.

[0027] S4: Preheat the bottom glaze layer, control the temperature at 60-70℃, use multi-layer inkjet printing to print decorative patterns on the bottom glaze layer, send it into a drying furnace and dry it at 110-115℃ for 80-90 minutes to form a three-dimensional layer; multi-layer inkjet printing is to first print a thinner basic pattern layer on the bottom glaze layer with a thickness of about 0.5-1mm, and then print the second and subsequent layers after low-temperature drying until the set thickness of the three-dimensional layer is reached. After each printing, dry it at 60-80℃ for 15-30 minutes.

[0028] By preheating the base glaze layer, the ingredients in the base glaze layer can be better activated, the adhesion of the base glaze can be improved, and the surface of the base glaze layer can be made drier and smoother, avoiding the blurring of the pattern caused by the diffusion of inkjet ink due to moisture, which is conducive to the clarity and accuracy of the inkjet printed pattern. Low-temperature drying after each printing can ensure the stability and adhesion of each layer of the pattern, avoid adhesion and deformation between layers, and print layer by layer to ensure the clarity, layering and three-dimensional sense of the three-dimensional layer, and achieve complex three-dimensional decorative pattern effects, such as the superposition of different colors and textures, making the three-dimensional relief effect more realistic. Through multi-layer inkjet printing, the texture, color and details of natural stone can be accurately reproduced on the base glaze layer, which can achieve a high degree of simulation effect and enhance the visual beauty and texture of the tile. By controlling the drying temperature and drying time, the inkjet ink is fully dried and solidified, ensuring the uniform drying and stability of the three-dimensional layer, thereby forming a stable three-dimensional layer.

[0029] S5: Apply the glaze slurry on the three-dimensional layer by multi-layer stacking glazing, put it into the kiln after drying, control the heating rate to 5-10℃ / minute, first fire it at 780-800℃ for 2-3 hours, then fire it at 1200-1220℃ for 6-8 hours to form a glaze layer; multi-layer stacking glazing is to apply glaze in layers on the three-dimensional layer, the total number of glazing layers is controlled between 3-5 layers, the thickness of each glazing is controlled between 0.1-0.2 mm, and dry it at 60-80℃ for 20-25 minutes after each glazing.

[0030] Low-temperature drying after each glazing can ensure that each layer of glaze is fully dried, prevent bubbles between layers, ensure the stability and adhesion of each layer of glaze, and avoid mutual influence between the surface glaze layers. Through multi-layer glazing, the thickness and uniformity of the glaze layer can be better controlled. Compared with one-time glazing, multi-layer glazing can better fill the tiny unevenness on the surface of the three-dimensional layer, thereby improving the flatness and glossiness of the glaze surface, and making the wear resistance level of the surface glaze layer reach above level 5, with excellent wear resistance. At the same time, multi-layer glazing also makes the glaze surface warmer, smoother and easier to clean. Low-temperature firing is used to ensure the initial bonding of the surface glaze layer, so that the organic matter in the glaze layer (such as additives such as alkyl sulfates and polyoxyethylene fatty alcohol ethers) slowly decomposes and volatilizes, and avoids the gas generated by the rapid combustion of organic matter to damage the glaze layer structure. High-temperature firing is used to fully melt the glaze layer, improve the density, hardness and glossiness of the glaze layer, and high-temperature firing can also promote the bonding between the glaze layer and the three-dimensional layer, making the structure of the entire ceramic tile more solid, and also helps to improve the wear resistance and corrosion resistance of the ceramic tile.

[0031] S6: Polishing the semi-finished product obtained in step S5 to form a polishing layer, thereby obtaining a three-dimensional relief ceramic tile.

[0032] Polishing makes the surface of ceramic tiles smoother and flatter, while enhancing anti-fouling and corrosion resistance. At the same time, the polishing layer also has good light transmittance, which can highlight the warm texture of the glaze layer. Example

[0033] A three-dimensional relief ceramic tile comprises, from bottom to top, a base layer, a base glaze layer, a three-dimensional layer, a glaze layer and a polishing layer. The base layer is located at the bottom layer of the ceramic tile and has a thickness of 10 mm. The base glaze layer is formed by applying a base glaze on the base layer and has a thickness of 0.8 mm. The three-dimensional layer is a pattern layer formed by inkjet printing on the base glaze layer and has a thickness of 2 mm. The glaze layer is formed by applying a top glaze on the three-dimensional layer and has a thickness of 0.6 mm. The polishing layer is formed by polishing the glaze layer.

[0034] The base glaze comprises the following raw materials in parts by weight: 20 parts of potassium feldspar, 10 parts of spodumene, 15 parts of kaolin, 12 parts of quartz powder, 18 parts of zircon sand, 2 parts of calcium carbonate, 5 parts of calcined dolomite, 3 parts of tricalcium phosphate, and 15 parts of ultra-white frit.

[0035] The chemical composition of the ultra-white frit is as follows: SiO2: 48%, Al2O3: 10%, ZrO2: 13%, MgO: 8%, Li2O: 2%, Na2O: 1%, ZnO: 11%, BaO: 2%, TiO2: 5%.

[0036] The glaze comprises the following raw materials in parts by weight: 20 parts of potassium feldspar, 10 parts of kaolin, 10 parts of quartz powder, 20 parts of strontium carbonate, 10 parts of sodium silicate, 4 parts of calcium carbonate, 4 parts of tricalcium phosphate, 0.2 parts of alkyl sulfate, 0.2 parts of polyoxyethylene fatty alcohol ether, and 21.6 parts of transparent frit.

[0037] The chemical composition of the transparent frit is as follows: SiO2: 51%, Al2O3: 12%, CaO: 6%, MgO: 2%, K2O: 2%, Na2O: 3%, B2O3: 6%, SrO: 8%, ZnO: 6%, Li2O: 1%, CaF2: 1%, SnO2: 2%.

[0038] The method for preparing a three-dimensional relief ceramic tile comprises the following steps: S1: Obtaining a base layer of ceramic tiles by batching, ball milling, sieving, spray granulation, aging, molding, drying, and sintering in a conventional manner; S2: According to the raw material composition of the base glaze and the top glaze, the ingredients are separately mixed, ball-milled, and sieved to obtain the base glaze slurry and the top glaze slurry; S3: applying a base glaze slurry on the base layer obtained in step S1, and drying the base glaze slurry at 45° C. for 40 minutes and then at 70° C. for 30 minutes in a gradient drying manner to form a base glaze layer after drying; S4: preheating the bottom glaze layer, controlling the temperature at 65°C, and printing the designed decorative pattern on the bottom glaze layer by multi-layer inkjet printing. First, print a thinner basic pattern layer on the bottom glaze layer with a thickness of 0.6mm, and then print the second and subsequent layers after low-temperature drying until the set thickness of the three-dimensional layer reaches 2mm. After each printing, dry it at 70°C for 25 minutes. After all the printing is completed, send it into a drying furnace and dry it at 110°C for 80 minutes to form a three-dimensional layer; S5: applying the top glaze slurry on the three-dimensional layer by multi-layer stacking glazing. The multi-layer stacking glazing is to apply glaze on the three-dimensional layer in layers. The total number of glazing layers is controlled between 3-5 layers. The thickness of each glazing is controlled between 0.2 mm. After each glazing, it is dried at 70°C for 25 minutes. After the last glazing and drying, it is placed in a kiln with a controlled heating rate of 6°C / minute. It is first fired at 780°C for 2.5 hours and then fired at 1210°C for 6 hours to form a top glaze layer. S6: Polishing the semi-finished product obtained in step S5 to form a polishing layer, thereby obtaining a three-dimensional relief ceramic tile.

[0039] Comparative Example: It is roughly the same as Example 1, except that the base glaze and the top glaze are prepared using the current conventional formula, the base glaze slurry is directly dried at 70°C for 50 minutes after application, the base glaze layer is not preheated before inkjet printing, the inkjet printing is not layered, the top glaze is sprayed in a single layer, and the rest is the same as Example 1.

[0040] By comparison, the ceramic tiles made in Example 1 have clearer and more realistic three-dimensional layer patterns, more layered textures, better three-dimensional effects, better visual effects, and improved finished product yields than the ceramic tiles made in the comparative example.

[0041] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A three-dimensional relief ceramic tile, characterized in that: From bottom to top, it includes a base layer, a base glaze layer, a three-dimensional layer, a glazed layer and a polishing layer. The base layer is located at the bottom layer of the ceramic tile and has a thickness of 8-10mm. The base glaze layer is formed after applying the base glaze on the base layer and has a thickness of 0.5-1mm. The three-dimensional layer is a pattern layer formed after inkjet printing on the base glaze layer and has a thickness of 1.5-2.5mm. The glazed layer is formed after applying the top glaze on the three-dimensional layer and has a thickness of 0.4-0.8mm. The polishing layer is formed after polishing the glazed layer.

2. The three-dimensional relief ceramic tile according to claim 1, characterized in that: The base glaze comprises the following raw materials in parts by weight: 20-25 parts of potassium feldspar, 8-10 parts of spodumene, 15-18 parts of kaolin, 10-12 parts of quartz powder, 16-20 parts of zircon sand, 2-4 parts of calcium carbonate, 4-6 parts of calcined dolomite, 2-4 parts of tricalcium phosphate, and 12-16 parts of ultra-white frit.

3. The three-dimensional relief ceramic tile according to claim 2, characterized in that: The chemical composition of the ultra-white frit is as follows: SiO2: 48-52%, Al2O3: 10-13%, ZrO2: 12-15%, MgO: 8-12%, Li2O: 1-3%, Na2O: 0-1%, ZnO: 8-10%, BaO: 2-4%, TiO2: 4-6%.

4. The three-dimensional relief ceramic tile according to claim 1, characterized in that: The glaze comprises the following raw materials in parts by weight: 20-25 parts of potassium feldspar, 10-12 parts of kaolin, 10-12 parts of quartz powder, 18-22 parts of strontium carbonate, 10-15 parts of sodium silicate, 3-5 parts of calcium carbonate, 2-4 parts of tricalcium phosphate, 0.1-0.3 parts of alkyl sulfate, 0.1-0.3 parts of polyoxyethylene fatty alcohol ether, and 20-25 parts of transparent frit.

5. The three-dimensional relief ceramic tile according to claim 4, characterized in that: The chemical composition of the transparent frit is as follows: SiO2: 50-55%, Al2O3: 10-12%, CaO: 5-8%, MgO: 2-5%, K2O: 2-5%, Na2O: 2-5%, B2O3: 6-8%, SrO: 8-10%, ZnO: 5-8%, Li2O: 1-3%, CaF2: 0.5-1%, SnO2: 1-3%.

6. A method for preparing the three-dimensional relief ceramic tile according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1: Obtaining the base layer of ceramic tiles through batching, ball milling, sieving, spray granulation, aging, molding, drying, and sintering; S2: According to the raw material composition of the base glaze and the top glaze, the base glaze slurry and the top glaze slurry are respectively prepared by mixing, ball milling and sieving; S3: applying a base glaze slurry on the base layer obtained in step S1, and drying it at 40-50° C. for 30-40 minutes and then at 60-70° C. for 20-30 minutes in a gradient drying manner to form a base glaze layer after drying; S4: preheating the bottom glaze layer, controlling the temperature at 60-70°C, printing a decorative pattern on the bottom glaze layer by multi-layer inkjet printing, and sending the layer into a drying furnace for drying at 110-115°C for 80-90 minutes to form a three-dimensional layer; S5: Applying the glaze slurry on the three-dimensional layer by multi-layer stacking glaze, putting it into the kiln after drying, controlling the heating rate to be 5-10℃ / min, first firing at a low temperature of 780-800℃ for 2-3 hours, and then firing at a high temperature of 1200-1220℃ for 6-8 hours to form a glaze layer; S6: Polishing the semi-finished product obtained in step S5 to form a polishing layer, thereby obtaining a three-dimensional relief ceramic tile.

7. The method for preparing a three-dimensional relief ceramic tile according to claim 6, characterized in that: The multi-layer inkjet printing in step S4 is to first print a thin base pattern layer on the base glaze layer with a thickness of about 0.5-1 mm, and then print the second and subsequent layers after low-temperature drying until the set thickness of the three-dimensional layer is reached. After each printing, it is dried at 60-80°C for 15-30 minutes.

8. The method for preparing a three-dimensional relief ceramic tile according to claim 6, characterized in that: The multi-layer glazing in step S5 is layered glazing on the three-dimensional layer, the total number of glazing layers is controlled between 3-5 layers, the thickness of each glazing is controlled between 0.1-0.2 mm, and each glazing is dried at 60-80° C. for 20-25 minutes.