A three-dimensional relief type ceramic tile and a method for manufacturing the same

Abstract

This invention discloses a three-dimensional relief ceramic tile and its preparation method. The 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 of the ceramic tile and has a thickness of 8-10 mm. The base glaze layer is formed after applying a base glaze to 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 after applying a surface glaze to the three-dimensional layer and has a thickness of 0.4-0.8 mm. The polishing layer is formed after polishing the glaze layer. This invention, through the combination of an ultra-white base glaze, a multi-layer inkjet-printed three-dimensional layer, and a surface glaze layer using multi-layer overlapping glazes, enables the three-dimensional relief ceramic tile to clearly reflect the texture and feel of the original stone, resulting in better visual impact and artistic expression, enhancing the three-dimensional effect and artistic appreciation of the ceramic tile, and meeting the market demand for high-end decorative ceramic tiles.

Description

Technical Field

[0001] This invention relates to the field of ceramic tile technology, and in particular to a three-dimensional relief ceramic tile and its preparation method. Background Technology

[0002] As people's living standards improve, their demands for decoration also increase. Ceramic tiles, as a common building material, directly affect the decorative effect through their appearance and texture. Traditional ceramic tiles are mostly flat, lacking three-dimensionality and artistry, making it difficult to meet modern consumers' pursuit of personalization and artistry. Consumers not only need ceramic tiles to have basic decorative and practical functions, but also hope that they can showcase unique artistic charm and individual expression. Especially in the high-end market, consumers have higher expectations for the texture and visual effect of tiles, preferring products that offer the feel and three-dimensional effect of natural stone. Against this backdrop, three-dimensional relief ceramic tiles have emerged, favored for their unique three-dimensionality and realistic decorative effect. These tiles not only increase the sense of layering and artistry in a space, but also create a unique decorative atmosphere through different relief patterns and textures. However, in existing technologies, most ceramic tiles achieving a three-dimensional relief effect suffer from relatively simple textures, unclear relief patterns, and an inability to reflect the natural effect of the original stone's texture and layering. Therefore, it is necessary to develop a ceramic tile with a clear pattern that can reflect the texture and feel of natural stone in order to meet the market demand for high-quality decorative products. Summary of the Invention

[0003] The purpose of this invention is to provide a three-dimensional relief ceramic tile and its preparation method. By combining an ultra-white base glaze, a multi-layer inkjet printed three-dimensional layer, and a surface glaze layer with multiple layers of overlapping glazes, 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 objectives, the present invention provides the following technical solution:

[0005] 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 of the ceramic tile and has a thickness of 8-10 mm. The base glaze layer is formed after applying a base glaze to 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 after applying a surface glaze to the three-dimensional layer and has a thickness of 0.4-0.8 mm. The polishing layer is formed after polishing the glaze layer.

[0006] Furthermore, the base glaze comprises the following raw materials in parts by weight: 20-25 parts potassium feldspar, 8-10 parts spodumene, 15-18 parts kaolin, 10-12 parts quartz powder, 16-20 parts zircon sand, 2-4 parts calcium carbonate, 4-6 parts calcined dolomite, 2-4 parts tricalcium phosphate, and 12-16 parts ultra-white frit.

[0007] 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%.

[0008] Furthermore, the surface glaze comprises the following raw materials in parts by weight: 20-25 parts potassium feldspar, 10-12 parts kaolin, 10-12 parts quartz powder, 18-22 parts strontium carbonate, 10-15 parts sodium silicate, 3-5 parts calcium carbonate, 2-4 parts tricalcium phosphate, 0.1-0.3 parts alkyl sulfate, 0.1-0.3 parts polyoxyethylene fatty alcohol ether, and 20-25 parts transparent frit.

[0009] 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%.

[0010] The preparation method of three-dimensional relief ceramic tiles includes the following steps:

[0011] S1: The base layer of ceramic tiles is obtained through batching, ball milling, sieving, spray granulation, aging, molding, drying, and firing.

[0012] S2: Prepare the base glaze and top glaze slurry according to their raw material composition, ball mill them, and sieve them to obtain the base glaze slurry and top glaze slurry;

[0013] S3: Apply a base glaze slurry to the base layer obtained in step S1, and use a gradient drying method. First, dry at 40-50℃ for 30-40 minutes, and then dry at 60-70℃ for 20-30 minutes. After drying, a base glaze layer is formed.

[0014] S4: Preheat the base glaze layer at 60-70℃, print the decorative pattern on the base glaze layer using multi-layer inkjet printing, and dry it in a drying oven at 110-115℃ for 80-90 minutes to form a three-dimensional layer.

[0015] S5: Apply the surface glaze slurry to the three-dimensional layer using a multi-layer glazing method. After drying, place it in the kiln and control the heating rate to be 5-10℃ / minute. First, fire at a low temperature of 780-800℃ for 2-3 hours, and then fire at a high temperature of 1200-1220℃ for 6-8 hours to form the surface glaze layer.

[0016] S6: Polish the semi-finished product obtained in step S5 to form a polished layer, thus obtaining a three-dimensional relief ceramic tile.

[0017] Furthermore, the multi-layer inkjet printing described in step S4 involves first printing a thin basic pattern layer on the base glaze layer, with a thickness of about 0.5-1mm. After low-temperature drying, the second and subsequent layers are printed until the set thickness of the three-dimensional layer is reached. After each printing, the layer is dried at 60-80℃ for 15-30 minutes.

[0018] Furthermore, the multi-layer glazing described in step S5 involves applying glaze in layers on a three-dimensional layer, with the total number of glazing layers controlled between 3 and 5, and the thickness of each glazing layer controlled between 0.1 and 0.2 mm. After each glazing, the layers are dried at 60-80°C for 20-25 minutes.

[0019] Compared with the prior art, the beneficial effects of the present invention are:

[0020] This invention combines an ultra-white base glaze, a multi-layer inkjet-printed three-dimensional layer, and a surface glaze layer, using a multi-layered glazing technique. This allows the three-dimensional relief ceramic tile to clearly reflect the texture and feel of the original stone, resulting in better visual impact and artistic expression. It enhances the three-dimensional effect and artistic appreciation of the ceramic tile, meeting the market demand for high-end decorative ceramic tiles.

[0021] 1. The base glaze formula used in this 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, more vivid and lifelike.

[0022] 2. This invention uses multi-layer inkjet printing to accurately replicate the details and texture of the original stone on the base glaze layer, perfectly presenting the texture of the original stone, making the decorative effect of ceramic tiles closer to natural stone, and enhancing the decorative value and market competitiveness of the product.

[0023] 3. This invention uses a multi-layer glazing process to form a uniform, smooth, and three-dimensional glaze layer, making the glaze surface more warm and lustrous, which greatly enhances the decorative effect and user experience of ceramic tiles. Detailed Implementation

[0024] To make the technical problems solved, technical solutions, and beneficial effects of the present invention clearer, the present invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the present invention and are not intended to limit the present invention.

[0025] 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 of the ceramic tile and has a thickness of 8-10 mm. The base glaze layer is formed after applying a base glaze to 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 after applying a surface glaze to the three-dimensional layer and has a thickness of 0.4-0.8 mm. The polishing layer is formed after polishing the glaze layer.

[0026] The base glaze comprises the following raw materials in parts by weight: 20-25 parts potassium feldspar, 8-10 parts spodumene, 15-18 parts kaolin, 10-12 parts quartz powder, 16-20 parts zircon sand, 2-4 parts calcium carbonate, 4-6 parts calcined dolomite, 2-4 parts tricalcium phosphate, and 12-16 parts ultra-white frit.

[0027] Potassium feldspar, as a network-forming agent, helps form the network structure of the glaze, enhancing its mechanical strength and chemical stability. At high temperatures, it provides fluxing action, lowering the melting temperature of the glaze and making it easier to form a uniform glassy substance during firing. A proportion of 20-25% ensures sufficient fluxing effect without compromising the chemical stability and other properties of the glaze due to excessive content. Spodumene, as an auxiliary flux, can improve the whiteness of the glaze, while also enhancing its mechanical strength and thermal stability, preventing glaze cracking. A proportion of 8-10% ensures synergistic effects with other raw materials such as potassium feldspar, further optimizing the firing performance of the base glaze. Kaolin, as a binder and filler in the glaze, improves its plasticity and formability, aiding in the formation of the glaze layer and its bonding with the base layer. It also improves the whiteness and hiding power of the glaze surface and helps adjust the coefficient of thermal expansion. A proportion of 15-18% ensures that the glaze does not settle or separate during application, maintaining a uniform glaze distribution. Quartz powder, primarily composed of silicon dioxide (SiO2), is also a network-forming agent. It works with potassium feldspar to form the framework of the base glaze, while simultaneously improving the mechanical strength and wear resistance of the glaze, and increasing its chemical stability. During firing, quartz powder can broaden the melting temperature range of the glaze, helping to control the firing process and resulting in a more uniform glaze surface. A 10-12% concentration can effectively improve the hardness, wear resistance, and chemical stability of the glaze without causing excessively high melting temperatures. Zirconium sand can enhance the whiteness and hiding power of the glaze, while also strengthening its chemical stability and wear resistance. This helps to form a uniform, stable, and well-covering pure white base glaze. A 16-20% concentration ensures that zirconium sand fully exerts its effects in improving whiteness, hiding power, chemical stability, and wear resistance, resulting in clearer and more durable three-dimensional patterns. Calcium carbonate, acting as a flux, decomposes during firing to produce calcium oxide. Calcium oxide can react with other components, lowering the firing temperature of the base glaze, increasing its fluidity, and facilitating uniform coating. It also improves the gloss of the base glaze. A 2-4% concentration helps lower the melting point of the glaze while regulating its fluidity. Calcined dolomite improves the mechanical strength and thermal stability of the glaze, while also helping to adjust its coefficient of thermal expansion, ensuring compatibility between the glaze and the body. A 4-6% concentration acts as a flux and improves performance without affecting the firing temperature of the base glaze. Tricalcium phosphate enhances the adhesion and abrasion resistance of the glaze. A 2-4% concentration strengthens the adhesion, making the glaze surface more robust and durable. Ultra-white frit provides high whiteness and gloss to the glaze, resulting in a cleaner, brighter finish.

[0028] The chemical composition of the super 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%.

[0029] SiO2, as the main network forming agent, provides a basic glass network structure for the frit at a proportion of 48-52%, which helps improve the stability and high-temperature resistance of the glaze. Al2O3 acts as a flux, lowering the melting point of the glaze, promoting the uniform distribution and bonding of other components, and enhancing the chemical stability of the glaze. A proportion of 10-13% can effectively lower the melting point and increase the fluidity of the glaze. ZrO2 helps improve the whiteness and gloss of the base glaze, enhances its ability to cover the color of the base layer, and also enhances the wear resistance and chemical stability of the glaze. A proportion of 12-15% can effectively improve the optical properties of the glaze, making the glaze surface whiter and brighter. MgO acts as a flux and stabilizer in the glaze, helping to lower the melting temperature and improve the fluidity and uniformity of the glaze. Simultaneously, MgO can enhance the gloss and whiteness of the glaze surface, improving the overall aesthetics of the ceramic tile. A proportion of 8-12% can effectively optimize the melting performance and surface quality of the glaze. Li₂O has a low melting point, which promotes the melting and flow of glazes and helps improve the gloss and transparency of the glaze surface, making it brighter and cleaner. However, its proportion should not be too high, otherwise it will affect the hardness of the glaze. Na₂O, as a flux, can lower the melting temperature of the frit, improve its fluidity, help with the uniform coating of the glaze, and improve the thermal expansion properties of the glaze. It also improves the gloss and whiteness of the glaze. However, its proportion should not be too high, otherwise it will lead to a decrease in the chemical stability of the glaze. ZnO acts as a whitening agent and opacifier in glazes, significantly improving the whiteness, gloss, and opacity of the glaze surface. As a stabilizer, it can also prevent the glaze from discoloring at high temperatures. Its proportion of 8-10% can ensure high whiteness and stability of the glaze surface. BaO can increase the refractive index of the glaze, thereby improving the gloss of ceramic tiles. It also acts as a flux to some extent, aiding in the melting and sintering of the frit. A 2-4% BaO content can improve the refractive index and gloss of the base glaze without affecting other properties. However, an excessively high BaO content can negatively impact the chemical and color stability of the base glaze. TiO2, as an opacifier, significantly improves the whiteness, opacity, and hiding power of the glaze. It scatters light, making the base glaze appear whiter, and can cover impurities or color inconsistencies, improving appearance quality. It also enhances the mechanical strength and chemical stability of the glaze. A 4-6% TiO2 content effectively improves hiding power and whiteness. An excessively high TiO2 content may affect the color stability of the base glaze, leading to a yellowish tint.

[0030] The glaze comprises the following raw materials in parts by weight: 20-25 parts potassium feldspar, 10-12 parts kaolin, 10-12 parts quartz powder, 18-22 parts strontium carbonate, 10-15 parts sodium silicate, 3-5 parts calcium carbonate, 2-4 parts tricalcium phosphate, 0.1-0.3 parts alkyl sulfate, 0.1-0.3 parts polyoxyethylene fatty alcohol ether, and 20-25 parts transparent frit.

[0031] Potassium feldspar, kaolin, quartz powder, calcium carbonate, and tricalcium phosphate play the same roles in the top glaze as in the base glaze. Strontium carbonate (SrCO3) is the main high-gloss component. During firing, strontium carbonate decomposes to produce strontium oxide, which enhances the gloss and transparency of the glaze, while also improving its smoothness. This contributes to the top glaze achieving high gloss, high transparency, and a smooth feel. A concentration of 18-22% ensures high gloss and makes three-dimensional patterns more vivid. Sodium silicate (Na2SiO3) improves the transparency and fluidity of the glaze, helping to form a smooth surface. A concentration of 10-15% effectively enhances the gloss of the glaze. Alkyl sulfates, as surfactants, improve the stability and flowability of glaze slurries, while also helping to remove impurities from the glaze, maintaining its purity and smoothness, and enhancing its transparency and gloss. Polyoxyethylene fatty alcohol ethers, as wetting agents, improve the wettability and adhesion of the glaze. The ratio of alkyl sulfates to polyoxyethylene fatty alcohol ethers should not be too high, otherwise it will affect the chemical stability of the glaze. Transparent frits can improve the melting properties and flowability of the glaze, making the glaze surface smoother and more transparent.

[0032] The specific 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%.

[0033] In the transparent frit, SiO2 acts as a network forming agent, creating a robust glassy structure that improves the durability and gloss of the glaze. Al2O3 acts as a flux, lowering the melting point of the glaze, increasing its fluidity, and enhancing its transparency and gloss. CaO and MgO improve the heat resistance and stability of the glaze, while also enhancing its gloss. K2O and Na2O adjust the coefficient of thermal expansion of the glaze to match that of the ceramic matrix, reducing stress and cracking. K2O also helps improve the hardness and wear resistance of the glaze. B2O3... To lower the melting temperature of the glaze and improve its fluidity, thus helping to form a smooth surface and high gloss, SrO can improve the gloss and transparency of the glaze. In synergy with strontium carbonate, it enhances the high gloss of the glaze. ZnO can improve the hardness and gloss of the glaze and enhance its scratch resistance. Li2O further lowers the melting temperature of the glaze and improves its transparency and gloss. 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 while enhancing its wear resistance.

[0034] The preparation method of three-dimensional relief ceramic tiles includes the following steps:

[0035] S1: The base layer of ceramic tiles is obtained through batching, ball milling, sieving, spray granulation, aging, molding, drying, and firing.

[0036] S2: Prepare the base glaze and top glaze slurry according to their raw material composition, ball mill them, and sieve them to obtain the base glaze slurry and top glaze slurry;

[0037] S3: Apply a base glaze slurry to the base layer obtained in step S1, and use a gradient drying method. First, dry at 40-50℃ for 30-40 minutes, and then dry at 60-70℃ for 20-30 minutes. After drying, a base glaze layer is formed.

[0038] Gradient drying can effectively remove moisture and air from the glaze layer, allowing the moisture in the base glaze layer to evaporate slowly and evenly. This avoids cracks in the base glaze layer caused by drying stress, improves the quality of the glaze layer, and reduces defects during the firing process.

[0039] S4: Preheat the base glaze layer at 60-70℃. Use multi-layer inkjet printing to print decorative patterns on the base glaze layer. Then, put it into a drying oven at 110-115℃ for 80-90 minutes to form a three-dimensional layer. Multi-layer inkjet printing first prints a thin base pattern layer on the base glaze layer, about 0.5-1mm thick. After drying at a low temperature, the second and subsequent layers are printed until the set thickness of the three-dimensional layer is reached. After each printing, dry at 60-80℃ for 15-30 minutes.

[0040] Preheating the base glaze layer activates its components, improving adhesion and ensuring a drier, smoother surface. This prevents inkjet ink from spreading due to moisture, resulting in blurred patterns and enhancing the clarity and accuracy of the printed design. Low-temperature drying after each print ensures stability and adhesion for each layer, preventing adhesion and deformation. Layer-by-layer printing maintains clarity, depth, and three-dimensionality, enabling complex decorative patterns such as layered colors and textures for a more realistic relief effect. Multi-layer inkjet printing precisely replicates the texture, color, and details of natural stone onto the base glaze layer, achieving a high degree of simulation and enhancing the visual appeal and texture of the tiles. Controlling drying temperature and time ensures thorough drying and curing of the inkjet ink, guaranteeing uniform drying and stability of the three-dimensional layer, resulting in a stable layer.

[0041] S5: Apply the surface glaze slurry to the three-dimensional layer using a multi-layer glazing method. After drying, place it in the kiln and control the heating rate to 5-10℃ / minute. First, fire at a low temperature of 780-800℃ for 2-3 hours, and then fire at a high temperature of 1200-1220℃ for 6-8 hours to form the surface glaze layer. The multi-layer glazing involves applying glaze in layers on the three-dimensional layer, with the total number of glaze layers controlled between 3-5. The thickness of each glaze application is controlled between 0.1-0.2 mm. After each glaze application, dry at 60-80℃ for 20-25 minutes.

[0042] Low-temperature drying after each glazing application ensures thorough drying of each glaze layer, preventing issues such as air bubbles between layers. This ensures the stability and adhesion of each glaze layer and avoids mutual interference between glaze layers. Multi-layer glazing allows for better control of glaze thickness and uniformity. Compared to single-application glazing, multi-layer glazing better fills in minor unevenness on the surface of the three-dimensional layer, improving the smoothness and gloss of the glaze surface and achieving an abrasion resistance rating of 5 or higher, demonstrating excellent wear resistance. Simultaneously, multi-layer glazing makes the glaze surface smoother and easier to clean. Low-temperature firing ensures initial bonding of the glaze layers, allowing organic matter (such as alkyl sulfates and polyoxyethylene fatty alcohol ethers) in the glaze to slowly decompose and volatilize, preventing damage to the glaze structure from gases produced by rapid combustion of organic matter. High-temperature firing ensures complete melting of the glaze layer, improving its density, hardness, and gloss. High-temperature firing also promotes bonding between the glaze layer and the three-dimensional layer, making the overall ceramic tile structure more robust and contributing to improved wear resistance and corrosion resistance.

[0043] S6: Polish the semi-finished product obtained in step S5 to form a polished layer, thus obtaining a three-dimensional relief ceramic tile.

[0044] Polishing makes the surface of ceramic tiles smoother and flatter, while also enhancing their stain resistance and corrosion resistance. At the same time, the polished layer also has good light transmittance, highlighting the warm texture of the glaze layer. Example

[0045] 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 of the ceramic tile and is 10mm thick. The base glaze layer is formed after applying a base glaze to the base layer and is 0.8mm thick. The three-dimensional layer is a pattern layer formed by inkjet printing on the base glaze layer and is 2mm thick. The glaze layer is formed after applying a surface glaze to the three-dimensional layer and is 0.6mm thick. The polishing layer is formed after polishing the glaze layer.

[0046] The base glaze comprises the following raw materials in parts by weight: 20 parts potassium feldspar, 10 parts spodumene, 15 parts kaolin, 12 parts quartz powder, 18 parts zircon sand, 2 parts calcium carbonate, 5 parts calcined dolomite, 3 parts tricalcium phosphate, and 15 parts ultra-white frit.

[0047] The chemical composition of the super white frit is as follows: SiO2: 48%, Al2O3: 10%, ZrO2: 13%, MgO: 8%, Li2O: 2%, Na2O: 1%, ZnO: 11%, BaO: 2%, TiO2: 5%.

[0048] The glaze comprises the following raw materials in parts by weight: 20 parts potassium feldspar, 10 parts kaolin, 10 parts quartz powder, 20 parts strontium carbonate, 10 parts sodium silicate, 4 parts calcium carbonate, 4 parts tricalcium phosphate, 0.2 parts alkyl sulfate, 0.2 parts polyoxyethylene fatty alcohol ether, and 21.6 parts transparent frit.

[0049] The chemical composition of the transparent molten metal 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%.

[0050] The preparation method of three-dimensional relief ceramic tiles includes the following steps:

[0051] S1: The base layer of ceramic tiles is obtained by conventional methods, including batching, ball milling, sieving, spray granulation, aging, molding, drying, and firing.

[0052] S2: Prepare the base glaze and top glaze slurry according to their raw material composition, ball mill them, and sieve them to obtain the base glaze slurry and top glaze slurry;

[0053] S3: Apply a base glaze slurry to the base layer obtained in step S1, and use a gradient drying method. First, dry at 45°C for 40 minutes, and then dry at 70°C for 30 minutes. After drying, a base glaze layer is formed.

[0054] S4: Preheat the base glaze layer at 65℃. Use multi-layer inkjet printing to print the designed decorative pattern on the base glaze layer. First, print a thin base pattern layer with a thickness of 0.6mm on the base glaze layer. After low-temperature drying, print the second and subsequent layers until the set thickness of the three-dimensional layer of 2mm is reached. After each printing, dry at 70℃ for 25 minutes. After all printing is completed, send it to the drying oven at 110℃ for 80 minutes to form the three-dimensional layer.

[0055] S5: Apply the surface glaze slurry to the three-dimensional layer using a multi-layer glazing method. The multi-layer glazing involves applying glaze in layers on the three-dimensional layer, with the total number of glaze layers controlled between 3 and 5. The thickness of each glaze layer is controlled between 0.2 mm. After each glaze layer is applied, dry it at 70℃ for 25 minutes. After the last glaze layer is dried, place it in the kiln and control the heating rate to 6℃ / minute. First, fire it at a low temperature of 780℃ for 2.5 hours, and then fire it at a high temperature of 1210℃ for 6 hours to form the surface glaze layer.

[0056] S6: Polish the semi-finished product obtained in step S5 to form a polished layer, thus obtaining a three-dimensional relief ceramic tile.

[0057] Comparative example:

[0058] Similar to Example 1, except that the base glaze and top glaze are prepared using conventional formulas, the base glaze is dried directly at 70°C for 50 minutes after application, the base glaze layer is not preheated before inkjet printing, the inkjet printing is not done in layers, and the top glaze is applied using a single-layer spraying method. Everything else is the same as in Example 1.

[0059] By comparison, the ceramic tiles made in Example 1 have clearer, more realistic, and more layered three-dimensional patterns than those made in the comparative example, resulting in a better three-dimensional effect, superior visual appeal, and improved yield.

[0060] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A relief ceramic tile, characterized in that, From bottom to top, it includes a base layer, a bottom glaze layer, a three-dimensional layer, a glaze layer and a polishing layer, the base layer is located on the bottom layer of the ceramic tile, the thickness is 8-10mm, the bottom glaze layer is formed after applying the bottom glaze on the base layer, the thickness is 0.5-1mm, the three-dimensional layer is a pattern layer formed after inkjet printing on the bottom glaze layer, the thickness is 1.5-2.5mm, the glaze layer is formed after applying the surface glaze on the three-dimensional layer, the thickness is 0.4-0.8mm, and the polishing layer is formed after polishing treatment on the glaze layer; The preparation method of the three-dimensional relief type ceramic tile comprises the following steps: S1: obtaining the base layer of the ceramic tile by batching, ball milling, sieving, spray granulation, aging, molding, drying and burning; S2: respectively batching, ball milling and sieving the raw material compositions of the bottom glaze and the surface glaze to obtain the bottom glaze slurry and the surface glaze slurry; S3: applying the bottom glaze slurry on the base layer obtained in step S1, using gradient drying method, first drying at 40-50℃ for 30-40 minutes, and then drying at 60-70℃ for 20-30 minutes, and forming the bottom glaze layer after drying; S4: preheating the bottom glaze layer at a temperature of 60-70℃, using multi-layer inkjet printing method to print decorative patterns on the bottom glaze layer, and sending into the drying oven to dry at 110-115℃ for 80-90 minutes to form the three-dimensional layer; S5: applying the surface glaze slurry on the three-dimensional layer by multi-layer glazing method, drying, and then putting into the kiln, controlling the heating rate to be 5-10℃ / min, first low-temperature firing at 780-800℃ for 2-3 hours, and then high-temperature firing at 1200-1220℃ for 6-8 hours to form the surface glaze layer; S6: polishing the semi-finished product obtained in step S5 to form the polishing layer, thereby obtaining the three-dimensional relief type ceramic tile; The bottom glaze comprises the following raw materials 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 super white fused block.

2. The relief ceramic tile according to claim 1, characterized in that, The chemical composition of the super white fused block is specifically 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%, and TiO2: 4-6%.

3. The stereoscopic relief type ceramic tile according to claim 1, characterized in that, The surface glaze comprises the following raw materials 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 fused block.

4. The relief ceramic tile according to claim 3, 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%.

5. The stereoscopic relief type ceramic tile according to claim 1, wherein, The multi-layer inkjet printing in step S4 is to print a thinner base pattern layer on the bottom glaze layer, with a thickness of 0.5-1mm, and then to print the second layer and subsequent layers after low-temperature drying, until the set thickness of the three-dimensional layer is reached, and then to dry at 60-80℃ for 15-30 minutes after each printing.

6. The stereoscopic relief type ceramic tile according to claim 1, wherein, The multi-layer glazing in step S5 is to apply glaze on the three-dimensional layer in layers, with the total number of glazing layers controlled between 3-5 layers, and the thickness of each glazing layer controlled between 0.1-0.2mm, and then to dry at 60-80℃ for 20-25 minutes after each glazing.