Method for preparing polished tiles with partially mosaic pattern effects

Abstract

The present invention discloses a method for preparing a polished tile having a partially mosaic pattern effect, which belongs to the technical field of polished tile preparation and comprises the following steps: spreading powder; pressing and molding: the powder is pressed using a mold with a concave-convex structure to obtain a brick blank, forming a plurality of pits on the brick blank, and then drying the brick blank; spraying a transparent glaze; preparing a high-temperature resistant printing ink, using an inkjet printer to print a layer of 5-15 μm pattern on the bottom surface of the pit, and then using a 3D printer to print a layer of 0.5-1 mm glue on top of the pattern; applying dry particles on the entire surface of the brick blank; the dry particles are formed by mixing dry particles A with a diameter of 0.1-1 mm and dry particles B with a diameter of 1-2 mm in a ratio of 1:1; firing the brick blank in a kiln, and polishing. Through the above method, the polished tiles prepared by the present invention have clear boundaries and patterns, and flat polished tiles can be prepared. At the same time, the pattern is sealed in the pit, and there is no risk of falling off.

Description

Technical Field

[0001] The present invention relates to the technical field of polishing tile preparation, and in particular to a method for preparing a polishing tile partially having a mosaic pattern effect. Background Art

[0002] Polished tiles are widely used in the construction industry, for example as wall and floor coverings. With people's pursuit of aesthetics, polished tiles with mosaic patterns are becoming increasingly popular among consumers.

[0003] Traditional polished tiles with mosaic effect have the following preparation processes:

[0004] (1) Laying process: The polishing tile powder is laid out in a grid and pressed into shape; the polishing tile body is formed by firing; and the polished tile is obtained after polishing. However, since the pattern powder and the main body powder of the polishing tile are mixed during the pressing and firing process, the boundary between the mosaic pattern on the polishing tile and the main body of the polishing tile is not clear, resulting in poor pattern effect.

[0005] (2) Sheet material process: the sheet material with pattern is pressed into shape with polishing tile powder; fired to form the polishing tile embryo; polished to obtain polished tile. Although the boundary is relatively clear, the pattern is not clear enough, which also affects the final pattern effect.

[0006] (3) CN109293399B discloses a dry-granule brick with a stone-like embossed texture and its preparation method, which comprises applying a base glaze to the brick blank and then inkjet-printing a stone-like pattern; applying glue to the stone texture of the inkjet pattern and then spreading dry granules on the brick surface; removing the dry granules that are not firmly adhered; applying a covering glaze on the brick surface, and firing. However, this method directly prints the pattern on the base glaze and spreads the dry granules on the pattern. After firing, a raised pattern is formed on the brick surface, making it difficult to form a flat polished tile. In addition, the pattern and the base glaze are not firmly bonded, which poses a risk of falling off.

[0007] Based on this, the present invention designs a method for preparing polished tiles with a partial mosaic pattern effect to solve the above problems. Summary of the Invention

[0008] In view of the above-mentioned shortcomings of the prior art, the present invention provides a method for preparing a polished tile having a partial mosaic pattern effect.

[0009] To achieve the above objectives, the present invention is implemented through the following technical solutions:

[0010] A method for preparing a polished tile having a partially mosaic pattern effect comprises the following steps:

[0011] Step 1: Apply the powder material of the main body of the brick to the mold frame;

[0012] Step 2: Pressing and molding: The powder is pressed into a mold with a concave-convex structure to obtain a brick blank, forming a number of pits on the brick blank, and then the brick blank is dried;

[0013] Step 3: Spray transparent glaze: spray the glaze on the surface of the brick and then dry it;

[0014] Step 4: Prepare high-temperature resistant printing ink, use an inkjet printer to print a 5-15 μm pattern on the bottom surface of the pit, and then use a 3D printer to print a 0.5-1 mm layer of glue on top of the pattern;

[0015] Step 5: Apply dry particles to the entire surface of the brick; the dry particles are made by mixing dry particles A with a diameter of 0.1-1 mm and dry particles B with a diameter of 1-2 mm in a ratio of 1:1; dry particles B consist of two parts, the inner part of which is made of the same raw materials as dry particles A, and the outer part of dry particles B is coated with 0.2 mm glue and then dried;

[0016] Step 6: Remove the excess dry particles that are not stuck to the glue, leaving only the dry particles in the glue area above the pattern;

[0017] Step 9: The bricks are placed in a kiln and fired. During the firing process, the glue decomposes due to heat, and the dry particles fill the pits and form a vitreous structure, sealing the printed pattern in the pits.

[0018] Step 10: Use a polishing machine to polish the brick body to obtain a polished tile with a mosaic pattern effect in part.

[0019] Furthermore, in step 2, a plurality of regular or irregular shaped pits are formed on the brick.

[0020] Furthermore, in step 2, the depth of the pit is controlled to be 1 to 3 mm.

[0021] Furthermore, in step 4, the glue is transparent glue.

[0022] Furthermore, in step 4, the glue is methacrylic adhesive.

[0023] Furthermore, in step four, the raw materials of the high-temperature resistant printing ink include, by weight: 35 to 40 parts of acrylic resin, 1 to 3 parts of layered hydrotalcite, 0.03 to 0.1 parts of zirconium magnesium chromium spinel powder, 0.03 to 0.1 parts of tin oxide, 1 to 3 parts of porous silica nanospheres, 2 to 6 parts of nano-lithium titanate, and 1 to 5 parts of pigment.

[0024] Furthermore, in step five, the raw materials of the dry particles A include, by weight, 50-55 parts of waste glass, 5-7 parts of α-nano alumina, 3-5 parts of borax, 0.3-1 part of cerium oxide, 3-5 parts of zirconium silicate, 1-3 parts of potassium carbonate, and 0.8-1.3 parts of boron oxide.

[0025] Furthermore, in step five, the preparation method of the dry particles A is: mixing the raw materials and sintering them at 1500-1600° C. to form a liquid frit, and then grinding them to meet the corresponding fineness requirements to obtain dry particles of different shapes.

[0026] Furthermore, in step nine, the firing time is 45 to 70 minutes, the low-temperature preheating temperature is 900 to 1000°C, and the high-temperature firing temperature is 1150 to 1250°C.

[0027] Furthermore, the method further includes step seven: spraying a layer of glue with a thickness of 0.2 to 0.5 mm on the entire surface of the brick to fix the position of the dry particles. Step eight: drying the brick.

[0028] Compared with the prior art, the present invention has the following beneficial effects: after applying the powder, the present invention presses the brick into a blank with several pits through a mold, then sprays a transparent glaze, and then uses an inkjet printer to print a layer of 5-15μm pattern on the bottom surface of the pit, and then uses a 3D printer to print a layer of 0.5-1mm glue on top of the pattern. By applying two different diameters of dry particles and fixing the position of the dry particles with glue, the dry particles are filled into the pits during the firing process and form a glass structure, and the printed pattern is sealed in the pits. After polishing, the mosaic pattern on the polished tile has a clear boundary with the main body of the polished tile and the pattern is clear, the effect is good, and a flat polished tile can be prepared. At the same time, the pattern is sealed in the pit, and there is no risk of falling off. The polished tile prepared by the present invention has the advantages of high flexural strength and compressive strength. DETAILED DESCRIPTION

[0029] To make the purpose, technical solutions, and advantages of the embodiments of the present invention more clear, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0030] Example 1: In some embodiments, a method for preparing a polished tile having a partial mosaic effect comprises the following steps:

[0031] Step 1: Apply the powder material of the main body of the brick to the mold frame;

[0032] Step 2: Pressing and molding: The powder is pressed into a brick using a mold with a concave-convex structure, forming a number of regular or irregular shaped pits on the brick, and then the brick is dried;

[0033] The shape of the pit depends on the shape of the concave-convex structure of the mold. The sidewall of the pit can be a vertical surface, or a curved surface, an inclined surface, etc., such as a curved pit, a truncated cone pit, a rectangular pit, etc. The depth of the pit is controlled at 1mm;

[0034] Step 3: Spray transparent glaze: spray the glaze on the surface of the brick and then dry it;

[0035] Step 4: Weigh 35 parts of acrylic resin, 1 part of layered hydrotalcite, 0.03 parts of zirconium magnesium chromium spinel powder, 0.03 parts of tin oxide, 1 part of porous silica nanospheres, 2 parts of nano-lithium titanate, and 1 part of pigment, mix them evenly to obtain a high-temperature resistant printing ink, use an inkjet printer to print a 5 μm pattern on the bottom surface of the pit, and then use a 3D printer to print a 0.5 mm layer of glue (methacrylic adhesive) on top of the pattern;

[0036] Step 5: Apply dry granules to the entire surface of the brick. The dry granules are made by mixing dry granules A (0.1mm diameter) and dry granules B (1mm diameter) in a 1:1 ratio. Dry granules A are prepared by mixing 50 parts of waste glass, 5 parts of α-nanoalumina, 3 parts of borax, 0.3 parts of cerium oxide, 3 parts of zirconium silicate, 1 part of potassium carbonate, and 0.8 parts of boron oxide. The mixture is then sintered at 1600°C to form a liquid frit. The resulting liquid frit is then ground to meet the required fineness, yielding granules of varying shapes. Dry granules B consist of an inner and outer portion. The inner portion is made from the same raw materials as dry granules A, while the outer portion is coated with 0.2mm of glue and then dried.

[0037] Step 6: Remove the excess dry particles that are not stuck to the glue, leaving only the dry particles in the glue area above the pattern;

[0038] Step 7: Spray a layer of 0.2mm glue on the entire surface of the brick to fix the position of the dry particles;

[0039] Step 8: Drying the bricks;

[0040] Step 9: The bricks are placed in a kiln and fired for 45 minutes. The low-temperature preheating temperature is 900°C, and the high-temperature firing temperature is 1150°C. During the firing process, the glue decomposes due to heat, and the dry particles fill the pits and form a vitreous structure, sealing the printed pattern in the pits. The brick body has a tiny depression at the pattern.

[0041] Step 10: Use a polishing machine to polish the brick body to obtain a polished tile with a mosaic pattern effect in part.

[0042] Example 2: In some embodiments, a method for preparing a polished tile having a partially mosaic effect comprises the following steps:

[0043] Step 1: Apply the powder material of the main body of the brick to the mold frame;

[0044] Step 2: Pressing and molding: The powder is pressed into a brick using a mold with a concave-convex structure, forming a number of regular or irregular shaped pits on the brick, and then the brick is dried;

[0045] The shape of the pit depends on the shape of the concave-convex structure of the mold. The sidewall of the pit can be a vertical surface, or a curved surface, an inclined surface, etc., such as a hemispherical pit, a truncated cone pit, a rectangular pit, etc. The depth of the pit is controlled at 3mm;

[0046] Step 3: Spray transparent glaze: spray the glaze on the surface of the brick and then dry it;

[0047] Step 4: Weigh 40 parts of acrylic resin, 3 parts of layered hydrotalcite, 0.1 parts of zirconium magnesium chromium spinel powder, 0.1 parts of tin oxide, 3 parts of porous silica nanospheres, 6 parts of nano-lithium titanate, and 5 parts of pigment, mix them evenly to obtain a high-temperature resistant printing ink, use an inkjet printer to print a 15 μm pattern on the bottom surface of the pit, and then use a 3D printer to print a 1 mm layer of glue (methacrylic adhesive) on top of the pattern;

[0048] Step 5: Apply dry granules to the entire surface of the brick. The dry granules are made by mixing dry granules A (1mm in diameter) and dry granules B (2mm in diameter) in a 1:1 ratio. Dry granules A are prepared by mixing 55 parts of waste glass, 7 parts of α-nanoalumina, 5 parts of borax, 1 part of cerium oxide, 5 parts of zirconium silicate, 3 parts of potassium carbonate, and 1.3 parts of boron oxide. The mixture is then sintered at 1500°C to form a liquid frit. The resulting frit is then ground to meet the required fineness, yielding granules of varying shapes. Dry granules B consist of an inner and outer portion. The inner portion is made from the same raw materials as dry granules A, while the outer portion is coated with 0.2mm of glue and then dried.

[0049] Step 6: Remove the excess dry particles that are not stuck to the glue, leaving only the dry particles in the glue area above the pattern;

[0050] Step 7: Spray a layer of 0.5mm glue on the entire surface of the brick to fix the position of the dry particles;

[0051] Step 8: Drying the bricks;

[0052] Step 9: The bricks are placed in a kiln and fired for 70 minutes. The low-temperature preheating temperature is 1000°C, and the high-temperature firing temperature is 1250°C. During the firing process, the glue decomposes due to the heat, and the dry particles fill the pits and form a vitreous structure, sealing the printed pattern in the pits. The brick body has a tiny depression at the pattern.

[0053] Step 10: Use a polishing machine to polish the brick body to obtain a polished tile with a mosaic pattern effect in part.

[0054] Example 3: In some embodiments, a method for preparing a polished tile having a partially mosaic effect comprises the following steps:

[0055] Step 1: Apply the powder material of the main body of the brick to the mold frame;

[0056] Step 2: Pressing and molding: The powder is pressed into a brick using a mold with a concave-convex structure, forming a number of regular or irregular shaped pits on the brick, and then the brick is dried;

[0057] The shape of the pit depends on the shape of the concave-convex structure of the mold. The sidewall of the pit can be a vertical surface, or a curved surface, an inclined surface, etc., such as a hemispherical pit, a truncated cone pit, a rectangular pit, etc. The depth of the pit is controlled at 2.5mm;

[0058] Step 3: Spray transparent glaze: spray the glaze on the surface of the brick and then dry it;

[0059] Step 4: Weigh 37 parts of acrylic resin, 2 parts of layered hydrotalcite, 0.05 parts of zirconium magnesium chromium spinel powder, 0.07 parts of tin oxide, 1.8 parts of porous silica nanospheres, 4 parts of nano-lithium titanate, and 2 parts of pigment, mix them evenly to obtain a high-temperature resistant printing ink, use an inkjet printer to print a 10 μm pattern on the bottom surface of the pit, and then use a 3D printer to print a 0.7 mm layer of glue (methacrylic adhesive) on top of the pattern;

[0060] Step 5: Apply dry granules to the entire surface of the brick. The dry granules are made by mixing dry granules A (0.7mm diameter) and dry granules B (1.8mm diameter) in a 1:1 ratio. Dry granules A are prepared by mixing 52 parts of waste glass, 6 parts of α-nano alumina, 4 parts of borax, 0.5 parts of cerium oxide, 4 parts of zirconium silicate, 1.8 parts of potassium carbonate, and 0.9 parts of boron oxide. The mixture is then sintered at 1550°C to produce a liquid frit. The resulting frit is then ground to meet the required fineness, yielding granules of varying shapes. Dry granules B consist of an inner and outer portion. The inner portion is made from the same raw materials as dry granules A, while the outer portion is coated with 0.2mm glue and then dried.

[0061] Step 6: Remove the excess dry particles that are not stuck to the glue, leaving only the dry particles in the glue area above the pattern;

[0062] Step 7: Spray a layer of 0.3mm glue on the entire surface of the brick to fix the position of the dry particles;

[0063] Step 8: Drying the bricks;

[0064] Step 9: The bricks are placed in a kiln and fired for 60 minutes. The low-temperature preheating temperature is 955°C, and the high-temperature firing temperature is 1200°C. During the firing process, the glue decomposes due to the heat, and the dry particles fill the pits and form a vitreous structure, sealing the printed pattern in the pits. The brick body has a tiny depression at the pattern.

[0065] Step 10: Use a polishing machine to polish the brick body to obtain a polished tile with a mosaic pattern effect in part.

[0066] Comparative Example 1: The difference from Example 3 is that in step 5, the dry particles are replaced with dry particles with a diameter of 1.3 mm.

[0067] Comparative Example 2: The difference from Example 3 is that the high temperature resistant printing ink is replaced by commercially available ceramic inkjet printing ink.

[0068] Experimental Example: The clarity of the boundary between the mosaic pattern and the main body of the polished tiles of Examples 1-3 and Comparative Example 1, as well as the clarity of the pattern, were observed.

[0069] At the same time, the flexural strength and compressive strength of the polished tiles were tested (the raw materials of the bricks and glaze of the present invention refer to Example 3 of CN118164744B).

[0070] Table 1

[0071]

[0072]

[0073] As can be seen from Comparative Example 1, the use of two dry particles of different sizes and the coating of the glue layer on the outside of the dry particles B are beneficial to the composite strength of the dry particles A and the dry particles B in the early stage, which is beneficial to enhancing the bonding strength of the vitreous structure, ensuring a clear boundary of the vitreous structure, and avoiding the formation of a jagged boundary at the boundary where no powder penetrates.

[0074] It can be seen from Comparative Example 2 that the high-temperature resistant printing ink of the present invention has obvious high-temperature resistance effect, the polished tiles prepared have clear patterns, and there is no diffusion problem at the pattern boundary, and the pattern does not have the problem of inward shrinkage and deformation.

[0075] The present invention is to press a brick with several pits into a mold after applying powder, then spray a transparent glaze, and then use an inkjet printer to print a layer of 5-15μm pattern on the bottom surface of the pit, and then use a 3D printer to print a layer of 0.5-1mm glue on top of the pattern. By applying two different diameters of dry particles and fixing the position of the dry particles with glue, the dry particles are filled into the pits during the firing process and form a vitreous structure, and the printed pattern is sealed in the pits. After polishing, the mosaic pattern on the polished tile has a clear boundary with the main body of the polished tile and the pattern is clear, the effect is good, and a flat polished tile can be prepared. At the same time, the pattern is sealed in the pit, and there is no risk of falling off. The polished tile prepared by the present invention has the advantages of high flexural strength and compressive strength.

[0076] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements will not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A method for preparing a polished tile having a partially mosaic pattern effect, characterized in that: The following steps are involved: Step 1: Apply the powder material of the main body of the brick to the mold frame; Step 2: Pressing and molding: The powder is pressed into a mold with a concave-convex structure to obtain a brick blank, forming a number of pits on the brick blank, and then the brick blank is dried; Step 3: Spray transparent glaze: spray the glaze on the surface of the brick and then dry it; Step 4: Prepare high-temperature resistant printing ink, use an inkjet printer to print a 5-15 μm pattern on the bottom surface of the pit, and then use a 3D printer to print a 0.5-1 mm layer of glue on top of the pattern; Step 5: Apply dry particles to the entire surface of the brick; the dry particles are made by mixing dry particles A with a diameter of 0.1 to 1 mm and dry particles B with a diameter of 1 to 2 mm in a ratio of 1:1; dry particles B consist of two parts, the inner part of which is made of the same raw material as dry particles A, and the outer part of dry particles B is coated with glue and then dried; Step 6: Remove the excess dry particles that are not stuck to the glue, leaving only the dry particles in the glue area above the pattern; Step 7: Spray a layer of 0.2-0.5mm glue on the entire surface of the brick to fix the position of the dry particles; Step 8: Drying the bricks; Step 9: The bricks are placed in a kiln and fired. During the firing process, the glue decomposes due to heat, and the dry particles fill the pits and form a vitreous structure, sealing the printed pattern in the pits. Step 10: Use a polishing machine to polish the brick body to obtain a polished tile with a mosaic pattern effect in part.

2. The method for preparing a polished tile having a partial mosaic effect according to claim 1, characterized in that: In step 2, a number of regular or irregular shaped pits are formed on the brick.

3. The method for preparing a polished tile having a partial mosaic effect according to claim 2, characterized in that: In step 2, the depth of the pit is controlled to be 1 to 3 mm.

4. The method for preparing a polished tile having a partial mosaic effect according to claim 3, characterized in that: In step 4, the glue is transparent glue.

5. The method for preparing a polished tile having a partial mosaic effect according to claim 4, characterized in that: In step 4, the glue is methacrylic adhesive.

6. The method for preparing a polished tile having a partial mosaic effect according to claim 5, characterized in that: In step 4, the raw materials of the high-temperature resistant printing ink include, by weight: 35 to 40 parts of acrylic resin, 1 to 3 parts of layered hydrotalcite, 0.03 to 0.1 parts of zirconium magnesium chromium spinel powder, 0.03 to 0.1 parts of tin oxide, 1 to 3 parts of porous silica nanospheres, 2 to 6 parts of nano-lithium titanate, and 1 to 5 parts of pigment.

7. The method for preparing a polished tile having a partial mosaic effect according to claim 6, characterized in that: In step 5, the raw materials of the dry particles A include, by weight, 50-55 parts of waste glass, 5-7 parts of α-nano alumina, 3-5 parts of borax, 0.3-1 part of cerium oxide, 3-5 parts of zirconium silicate, 1-3 parts of potassium carbonate, and 0.8-1.3 parts of boron oxide.

8. The method for preparing a polished tile having a partial mosaic effect according to claim 7, characterized in that: In step 5, the preparation method of the dry particles A is as follows: the raw materials are mixed and then sintered at 1500-1600° C. to form a liquid frit, which is then ground to meet the corresponding fineness requirements to obtain dry particles of different shapes.

9. The method for preparing a polished tile having a partial mosaic effect according to claim 8, characterized in that: In step nine, the firing time is 45 to 70 minutes, the low-temperature preheating temperature is 900 to 1000°C, and the high-temperature firing temperature is 1150 to 1250°C.

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