An anti-cutting and rock-breaking slab and its preparation method

Abstract

The present invention relates to the technical field of architectural ceramics, and particularly relates to an anti-cutting and crack-resistant rock slab and a preparation method thereof, which includes a body layer, a base glaze layer, a decorative layer, and a polished glaze layer arranged in sequence from bottom to top; calculated by mass fraction, the raw materials of the body layer include: 1-3 parts of bentonite, 3-5 parts of magnesia soil, 22-28 parts of waste brick powder, 11-15 parts of washed mud, 28-35 parts of pyrophyllite, 12-16 parts of albite, and 8-12 parts of mixed mud; the chemical compositions of the waste brick powder, pyrophyllite, albite, and mixed mud all include SiO 2 , Al 2 O 3 , Fe 2 O 3 , TiO 2 , CaO, MgO, and K 2 O; calculated by mass percentage, the content of SiO 2 in the waste brick powder, pyrophyllite, albite, and the mixed mud is 65-75%, and the content of Al 2 O 3 is 13-20%; calculated by mass percentage, the mineral composition of the mixed mud includes 50-60% kaolinite and 40-50% free quartz. An anti-cutting and crack-resistant rock slab proposed by the present invention is beneficial to improving the anti-cutting and crack-resistant performance and strength on the premise of realizing low-temperature and fast firing.

Description

Technical Field

[0001] The present invention relates to the technical field of building ceramics, and particularly relates to a cut-resistant and crack-resistant rock slab and a preparation method thereof. Background Art

[0002] A rock slab is a new type of ceramic material made from natural raw materials through the processes of slurry ball milling, drying and spray tower granulation, pressed by a hydraulic press, and fired in a kiln. As a new variety in the field of building ceramics, the rock slab has been warmly welcomed by the market due to its strong durability, good hardness and strong decorative effect, and is widely used in fields such as home and kitchen boards.

[0003] Before use, the rock slab generally needs to be subjected to mechanical processing such as cutting, grinding, drilling and chamfering. However, since the rock slab is a brittle material, according to incomplete statistics, there will be a cutting crack probability of 10-20% during the mechanical processing of the rock slab products, which affects the later use of the products. In order to improve this shortcoming, the traditional technology adopts the method of slow firing at high temperature (the firing temperature exceeds 1260°C, and the firing cycle is 50-70 minutes), aiming to promote the development and growth of mullite crystals by slow firing at high temperature, increase the content of mullite crystals, and utilize the higher strength and thermal shock resistance of mullite crystals to enhance the cut-resistant and crack-resistant performance of the rock slab. However, although the above method has its effects, the dispersion of mullite crystals in the glass phase of the rock slab is usually not good, which easily leads to local agglomeration and enrichment of mullite crystals, thus causing stress concentration, and instead may exacerbate the generation of cutting cracks, resulting in limited improvement in the cut-resistant and crack-resistant performance. In addition, the above technical means of slow firing at high temperature not only increases the firing temperature but also prolongs the firing time, which is not conducive to realizing low-temperature and fast firing, reducing production energy consumption and improving the competitiveness of enterprises.

[0004] Since the cut-resistant and crack-resistant performance of the rock slab mainly depends on the green body layer, in order to overcome the above defects, in the prior art, the raw materials of the green body layer are improved, aiming to reduce the firing temperature and firing cycle, and on the premise of realizing low-temperature and fast firing, increase the content of mullite formed during firing and the dispersion of mullite crystals, thereby improving the cut-resistant and crack-resistant performance of the rock slab. However, due to the differences in the selection of raw materials and the preparation process, the produced rock slabs still have technical defects such as high firing temperature, long firing time and poor cut-resistant and crack-resistant performance. Summary of the Invention

[0005] The purpose of the present invention is to provide a cut-resistant and crack-resistant rock slab. By improving the raw materials of the green body layer, it is beneficial to improve the cut-resistant and crack-resistant performance and strength on the premise of reducing the firing temperature and firing cycle and realizing low-temperature and fast firing, so as to overcome the deficiencies in the prior art.

[0006] Another object of the present invention is to provide a method for preparing an anti-cutting and cracking rock slab, the firing temperature of which is as low as 1223 °C, the firing cycle is as low as 35-38 min, and the preparation method is simple and highly operable. It is beneficial to reduce the firing temperature and firing cycle, achieve low-temperature and fast firing, and improve the anti-cutting and cracking performance and strength to meet the actual use requirements.

[0007] To achieve this object, the present invention adopts the following technical solutions:

[0008] An anti-cutting and cracking rock slab, comprising a green body layer, a base glaze layer, a decorative layer and a polished glaze layer arranged in sequence from bottom to top;

[0009] Calculated by mass fraction, the raw materials of the green body layer include: 1-3 parts of bentonite, 3-5 parts of magnesian soil, 22-28 parts of waste brick powder, 11-15 parts of washed mud, 28-35 parts of pyrophyllite, 12-16 parts of albite and 8-12 parts of mixed mud;

[0010] The chemical compositions of the waste brick powder, the pyrophyllite, the albite and the mixed mud all include SiO 2 , Al 2 O 3 , Fe 2 O 3 , TiO 2 , CaO, MgO and K 2 O;

[0011] Calculated by mass percentage, the contents of SiO 2 in the waste brick powder, the pyrophyllite, the albite and the mixed mud are all 65-75%, and the contents of Al 2 O 3 are all 13-20%;

[0012] Calculated by mass percentage, the mineral components of the mixed mud include 50-60% kaolinite and 40-50% free quartz.

[0013] Furthermore, calculated by mass percentage, the chemical composition of the waste brick powder includes 65-66% SiO 2 , 18-19% Al 2 O 3 , 1.7-1.8% Fe 2 O 3 , 0.50-1% TiO 2 , 0.5-0.7% CaO, 1.7-1.8% MgO, 1.9-2% K 2 O and 2-2.1% Na 2 O, and the rest is loss on ignition;

[0014] The particle size of the waste brick powder is ≤ 0.85 mm.

[0015] Further, calculated by mass percentage, the chemical composition of the pyrophyllite includes SiO 2 70 - 73%, Al 2 O 3 18 - 20%, Fe 2 O 3 0.5 - 0.8%, TiO 2 0.4 - 0.5%, CaO 0.2 - 0.3%, MgO 0.1 - 0.2%, K 2 O 2.3 - 2.4% and Na 2 O 0.1 - 0.2%, and the rest is loss on ignition.

[0016] Further, calculated by mass percentage, the chemical composition of the albite includes SiO 2 68 - 70%, Al 2 O 3 16 - 18%, Fe 2 O 3 0.1 - 0.2%, TiO 2 0.05 - 0.1%, CaO 0.5 - 0.6%, MgO 0.1 - 0.2%, K 2 O 0.6 - 0.7% and Na 2 O 8 - 8.1%, and the rest is loss on ignition.

[0017] Further, calculated by mass percentage, the chemical composition of the mixed mud includes SiO 2 70 - 70.5%, Al 2 O 3 19 - 20%, Fe 2 O 3 1 - 1.2%, TiO 2 0.3 - 0.4%, CaO 0.4 - 0.5%, MgO 0.2 - 0.3%, K 2 O 1 - 1.1% and Na 2 O 0.2 - 0.3%, and the rest is loss on ignition.

[0018] Further, calculated by mass percentage, the chemical composition of the washed mud includes SiO 2 50 - 53%, Al 2 O 3 31 - 33%, Fe 2 O 3 1.4 - 1.5%, TiO 2 0.1 - 0.2%, CaO 0.1 - 0.2%, MgO 0.2 - 0.3%, K2 O 3 to 3.2% and Na 2 O 0.3 to 0.4%, with the balance being loss on ignition.

[0019] Further, calculated by mass percentage, the chemical composition of the magnesian soil includes SiO 2 62 to 63%, Al 2 O 3 5.7 to 5.8%, Fe 2 O 3 1.6 to 1.7%, TiO 2 0.1 to 0.2%, CaO 0.7 to 0.8%, MgO 19.5 to 20%, K 2 O 0.2 to 0.3% and Na 2 O 0.2 to 0.3%, with the balance being loss on ignition.

[0020] A method for preparing an anti-cutting and crack-resistant rock slab, used for preparing the above anti-cutting and crack-resistant rock slab, comprising the following steps:

[0021] A. After uniformly mixing the formula amounts of bentonite, magnesian soil, waste brick powder, washed mud, pyrophyllite, albite, and mixed mud, adding water for ball milling and sieving to obtain a slurry; spray granulating the slurry to obtain a green body; pressing the green body into shape and drying to obtain a green body layer; wherein, the fineness of the ball milling is 325 mesh sieve, and calculated by mass percentage, the residue on sieve is 1.3 to 1.8%;

[0022] B. Applying a base glaze on the surface of the green body layer to obtain a base glaze layer;

[0023] C. Printing color ink on the surface of the base glaze layer according to a preset pattern to obtain a decorative layer;

[0024] D. Applying a polished glaze on the surface of the decorative layer to obtain a polished glaze layer;

[0025] E. Drying and then firing in a kiln to obtain the anti-cutting and crack-resistant rock slab; wherein, the firing temperature of the anti-cutting and crack-resistant rock slab ≤ 1223 °C, and the firing cycle is 35 to 38 min.

[0026] Further, in step A, the specific method of sieving is: filtering the raw materials of the green body layer after adding water for ball milling successively through a 40-mesh sieve, a 60-mesh sieve, and an 80-mesh sieve once, and then filtering twice through an 110-mesh sieve.

[0027] Further, in step E, the firing curve of the anti-cutting and crack-resistant rock slab includes a preheating section, a first pre-temperature section, a strong oxidation section, a second pre-temperature section, a medium-temperature section, a high-temperature section, a transition section, a rapid cooling section, and a slow cooling section;

[0028] The top temperature of the preheating section rises from room temperature to 854 °C, and the bottom temperature rises from room temperature to 841 °C, taking 5 - 5.4 minutes;

[0029] The top temperature of the first pre-temperature section rises from 854 °C to 927 °C, and the bottom temperature rises from 841 °C to 1018 °C, taking 0.7 - 0.9 minutes;

[0030] The top temperature of the strong oxidation section rises from 927 °C to 1105 °C, and the bottom temperature rises from 1018 °C to 1148 °C, taking 1.5 - 1.8 minutes;

[0031] The top temperature of the second pre-temperature section drops from 1105 °C to 1030 °C and then rises from 1030 °C to 1080 °C, and the bottom temperature drops from 1148 °C to 1047 °C and then rises from 1047 °C to 1090 °C, taking 2.9 - 3 minutes;

[0032] The top temperature of the medium temperature section rises from 1080 °C to 1194 °C, and the bottom temperature rises from 1090 °C to 1205 °C, taking 5.5 - 5.8 minutes;

[0033] The top temperature of the high temperature section rises from 1194 °C to 1204 °C, and the bottom temperature rises from 1205 °C to 1223 °C, taking 4.5 - 5 minutes;

[0034] The top temperature of the transition section drops from 1204 °C to 950 °C, and the bottom temperature drops from 1223 °C to 950 °C, taking 2 - 2.1 minutes;

[0035] The top temperature of the rapid cooling section drops from 950 °C to 584 °C, and the bottom temperature drops from 950 °C to 586 °C, taking 2 - 2.5 minutes;

[0036] The top temperature of the slow cooling section drops from 584 °C to 97 °C, and the bottom temperature drops from 586 °C to 97 °C, taking 11 - 11.6 minutes.

[0037] The technical solution provided by the present invention may include the following beneficial effects:

[0038] 1. In this technical solution, a eutectic K 2 O-Na 2The quaternary composite flux of O-MgO-CaO can enable the green body layer to form a liquid phase in advance at a lower temperature. Due to the viscous flow and surface tension of the liquid phase, it can fill the voids inside the green body layer in advance, promote particle rearrangement, move closer to each other and bond into a whole. In addition, the basic oxides gradually enter the liquid phase, making the amount of liquid phase generated under the action of the quaternary composite flux gradually increase, and gradually appear in the green body layer in a stepped manner, and gradually dissolve other substances, resulting in the densification of the green body layer, which is beneficial to the purpose of reducing the firing temperature and shortening the firing cycle of the rock slab. In addition, the waste brick powder is a clinker that has been fired. When the clinker is added to the raw materials composed of other raw materials, it can promote the fast firing of the green body layer, further reduce the production energy consumption of the rock slab, and thus effectively promote the rapid firing of the rock slab and shorten the firing cycle. That is, through the above-mentioned various effects, the firing temperature of the rock slab in this application is as low as 1223 °C, and the firing cycle is reduced to 35-38 minutes, achieving the purpose of reducing the firing temperature and shortening the firing cycle.

[0039] 2. The waste brick powder not only contains a glass phase but also mullite crystals. Through scanning electron microscopy observation and phase location analysis, it can be clearly observed that the mullite crystals are interspersed in the glass phase. In addition, the chemical components of the waste brick powder all include Al 2 O 3 and SiO 2 , and the content of SiO 2 in the waste brick powder is 65-66%, and the content of Al 2 O 3 is 18-19%, belonging to the category of medium-aluminum and medium-silicon raw materials (referring to raw materials with a content of Al 2 O 3 of 13-20% and a content of SiO 2 of 65-75% calculated by mass percentage). The above-mentioned moderate silicon-aluminum content is beneficial to promoting the uniform precipitation and growth of mullite crystals generated by the reaction of Al 2 O 3 and SiO 2 in the waste brick powder in the glass phase. Therefore, when adding waste brick powder to the raw materials of the green body layer, it can effectively improve the dispersibility of mullite crystals in the glass phase. In addition, the waste brick powder itself has gone through multiple processes such as mixing, ball milling, firing, and crushing. And when the raw materials of the green body layer are used, the raw materials of the green body layer generally need to go through the above processes again, further optimizing the dispersibility of each phase in the waste brick powder and further promoting the uniform dispersion of mullite crystals in the glass phase.

[0040] 3. The chemical components of pyrophyllite, albite, and mixed mud all include Al 2 O 3 and SiO 2, and the main mineral component of the existing mixed mud is kaolinite. During the calcination process, Al in pyrophyllite, albite, and kaolinite 2 O 3 and SiO 2 can react to form mullite. Therefore, Al in pyrophyllite, albite, and the mixed mud 2 O 3 and SiO 2 can all participate in the formation reaction of mullite under calcination conditions. In addition, the three raw materials of pyrophyllite, albite, and the mixed mud all belong to the category of medium-aluminum and medium-silica raw materials. The above-mentioned moderate silicon-aluminum content is conducive to promoting the uniform precipitation and growth of mullite crystals formed by the reaction of Al 2 O 3 and SiO 2 in the glass phase. Detailed implementation mode

[0041] This technical solution provides an anti-cutting rock slab, which includes a blank layer, a base glaze layer, a decorative layer, and a polished glaze layer arranged in sequence from bottom to top;

[0042] Calculated by mass fraction, the raw materials of the blank layer include: 1-3 parts of bentonite, 3-5 parts of magnesian soil, 22-28 parts of waste brick powder, 11-15 parts of washed mud, 28-35 parts of pyrophyllite, 12-16 parts of albite, and 8-12 parts of mixed mud;

[0043] The chemical compositions of the waste brick powder, the pyrophyllite, the albite, and the mixed mud all include SiO 2 , Al 2 O 3 , Fe 2 O 3 , TiO 2 , CaO, MgO, and K 2 O;

[0044] Calculated by mass percentage, the content of SiO 2 in the waste brick powder, the pyrophyllite, the albite, and the mixed mud is all 65-75%, and the content of Al 2 O 3 is all 13-20%;

[0045] Calculated by mass percentage, the mineral components of the mixed mud include 50-60% kaolinite and 40-50% free quartz.

[0046] To solve the technical problems of high firing temperature, long firing time and poor anti-cutting crack resistance of slate in the existing technology, this technical solution proposes an anti-cutting crack slate. By optimizing the raw materials of the green body layer, the firing temperature of the slate is as low as 1223 °C, the firing cycle is as low as 35 - 38 min, and it has high strength and anti-cutting crack performance. Under the premise of realizing low-temperature and fast firing and reducing production energy consumption, the anti-cutting crack performance and strength of the slate can be improved to meet the actual use requirements.

[0047] Specifically, the raw materials of the green body layer include bentonite, magnesian soil, waste brick powder, pyrophyllite, albite and mixed mud. Among them, the main mineral component of magnesian soil is talc, which can introduce magnesium oxide into the formula system. The chemical compositions of waste brick powder, pyrophyllite, albite and mixed mud all include potassium oxide, sodium oxide, magnesium oxide and calcium oxide. Therefore, the above raw materials can also introduce potassium oxide, sodium oxide, magnesium oxide and calcium oxide into the formula system. Therefore, in this technical solution, a eutectic K 2 O-Na 2 O-MgO-CaO quaternary composite flux is generated by the combined action of these five raw materials, namely magnesian soil, waste brick powder, pyrophyllite, albite and mixed mud. The above quaternary composite flux can cause the green body layer to form a liquid phase in advance at a lower temperature. Due to the viscous flow and surface tension of the liquid phase, it can fill the voids inside the green body layer in advance, promote particle rearrangement, move closer to each other and bond to form a whole. In addition, alkaline oxides gradually enter the liquid phase, making the amount of liquid phase generated under the action of the quaternary composite flux gradually increase, and appear in the green body layer step by step, and gradually dissolve other substances, resulting in the green body layer becoming more dense, which is conducive to the slate achieving the purpose of reducing the firing temperature and shortening the firing cycle. In addition, waste brick powder is a fired clinker. When the clinker is added to the raw materials composed of other raw materials, it can promote the fast firing of the green body layer, further reduce the production energy consumption of the slate, and thus effectively promote the rapid firing of the slate and shorten the firing cycle. That is, through the above-mentioned multi-faceted effects of this application, the firing temperature of the slate is as low as 1223 °C, and the firing cycle is reduced to 35 - 38 min, achieving the purpose of reducing the firing temperature and shortening the firing cycle.

[0048] Secondly, waste brick powder not only contains a glass phase, but also contains mullite crystals. Through scanning electron microscope observation and phase location analysis, it can be clearly observed that mullite crystals are interspersed in the glass phase. In addition, the chemical compositions of waste brick powder all include Al 2 O 3 and SiO 2 , and the content of SiO 2 in waste brick powder is 65 - 66%, and the content of Al 2 O 3 is 18 - 19%, belonging to the category of medium-aluminum and medium-silicon raw materials (referring to calculated by mass percentage, Al 2 O3 has a content of 13 - 20% and SiO 2 has a content of 65 - 75% of the raw material). The above - moderate silicon - aluminum content is conducive to promoting the Al in the waste brick powder 2 O 3 and SiO 2 to react to form mullite crystals and precipitate and grow uniformly in the glass phase. Therefore, when adding waste brick powder to the raw material of the green body layer, it can effectively improve the dispersibility of mullite crystals in the glass phase. In addition, the waste brick powder itself has gone through multiple processes such as mixing, ball - milling, firing, and crushing. And when the raw material of the green body layer is used, the raw material of the green body layer generally needs to go through the above processes again, further optimizing the dispersibility of each phase in the waste brick powder and further promoting the uniform dispersion of mullite crystals in the glass phase.

[0049] In addition, the chemical compositions of pyrophyllite, albite, and mixed mud all contain Al 2 O 3 and SiO 2 , and the main mineral component of the existing mixed mud is kaolinite. During the calcination process, the Al in pyrophyllite, albite, and kaolinite 2 O 3 and SiO 2 can react to form mullite. Therefore, the Al in pyrophyllite, albite, and mixed mud 2 O 3 and SiO 2 can all participate in the formation reaction of mullite under calcination conditions. In addition, the three raw materials of pyrophyllite, albite, and mixed mud all belong to the category of medium - aluminum and medium - silicon raw materials. The above - moderate silicon - aluminum content is conducive to promoting the Al in the above raw materials 2 O 3 and SiO 2 to react to form mullite crystals and precipitate and grow uniformly in the glass phase.

[0050] Therefore, through the above - mentioned multiple effects of this technical solution, the mullite crystals in the green body layer are uniformly dispersed in the glass phase, not only effectively reducing the stress concentration points (i.e., potential defect areas) in the glass phase, but also greatly hindering the cracking tendency of the glass phase, thereby significantly improving the anti - cutting crack performance of the rock slab. In addition, the uniform distribution of mullite crystals also significantly improves the thermal stability of the material, which is conducive to the rock slab better coping with thermal stress during the temperature change process, reducing the crack risk caused by uneven thermal expansion and contraction, and also conducive to improving the anti - cutting crack performance.

[0051] Furthermore, the existing K 2 O and Na 2O fluxing system. Before the calcination temperature reaches the eutectic point, the amount of liquid phase that appears is very small. However, when the calcination temperature reaches the eutectic point, a large amount of liquid phase will immediately appear and rapidly increase with the increase of temperature. The rapid appearance of a large amount of liquid phase may make the stress distribution inside the green body layer uneven, affecting the anti-cutting and cracking performance of the rock slab. And in the green body layer of this technical solution, due to the use of K 2 O-Na 2 O-MgO-CaO quaternary composite flux, the liquid phase generated during the melting of the raw materials is in a stepped shape and is a continuous stepped shape, resulting in the densification of the green body layer and also being beneficial to improving the anti-cutting and cracking performance of the rock slab.

[0052] In summary, this technical solution effectively improves the anti-cutting and cracking performance of the rock slab by enhancing the dispersion of mullite crystals in the glass phase and enhancing the densification of the green body layer.

[0053] It should be noted that mullite crystals have high strength and good thermal stability, and their uniform distribution can enhance the internal structure of the rock slab, thereby improving the overall strength of the rock slab; at the same time, the enhancement of the densification of the green body layer can reduce pores and defects and improve the overall structural integrity of the material, thereby further enhancing the strength of the rock slab; in addition, the four raw materials of waste brick powder, pyrophyllite, albite and mixed mud, SiO 2 and Al 2 O 3 are beneficial to promoting the formation of more mullite crystals and further enhancing the overall strength of the rock slab.

[0054] Furthermore, the raw materials of the green body layer also include bentonite and washed mud. Among them, bentonite can tightly combine with other raw material particles to form a stable bonding structure, which has a positive effect on improving the strength of the rock slab; the washed mud has a more compact internal structure and enhanced bonding force between particles after purification treatment, which also helps to improve the strength of the rock slab.

[0055] In summary, through the comprehensive exertion of various effects, the overall strength of the rock slab is effectively improved in this technical solution. It should be noted that bentonite has extremely high adsorption, expansibility and dispersibility, enabling the raw materials of the green body layer to form a stable suspension in water, with good thixotropy and lubricity, thereby increasing the plasticity of the green body layer; the clay particles in the washed mud will flocculate under the action of water, forming a colloidal connection between the raw materials of the green body layer, thereby increasing the plasticity of the green body layer, and the plastic components of the washed mud are beneficial to enhancing the formability and stability of the green body layer; further, the mixed mud is composed of a variety of soils or minerals with different components and properties. The clay particles in the mixed mud will also flocculate under the action of water, forming a colloidal connection between the raw materials of the green body layer, thereby increasing the plasticity of the green body layer. At the same time, the strength of the mixed mud is usually relatively high, which is beneficial to ensuring the strength of the green body layer after drying, and thus is also beneficial to improving its overall plasticity. Therefore, the plasticity of the green body layer is improved through the mutual cooperation of the three raw materials of bentonite, washed mud and mixed mud in this technical solution.

[0056] Finally, calculated by mass parts, the raw materials of the green body layer include: 1-3 parts of bentonite, 3-5 parts of magnesian soil, 22-28 parts of waste brick powder, 11-15 parts of washed mud, 28-35 parts of pyrophyllite, 12-16 parts of albite and 8-12 parts of mixed mud. By limiting the components in the raw materials of the green body layer, it is beneficial for each raw material to fully exert its own advantages, thereby ensuring the performance of the rock slab.

[0057] It should be noted that in the prior art, washed mud and bauxite are used in combination to increase the aluminum content in the formula. The mineral composition of bauxite is mainly diaspore, and diaspore will decompose to produce corundum α-Al 2 O 3 , and the reaction activity of corundum is relatively low, making it difficult to melt or react with other raw materials in the formula, resulting in pores in the system, thereby affecting the anti-cutting and cracking performance. The sintering temperature of diaspore is relatively high, which is not conducive to the overall sintering process. Therefore, in order to meet the requirements for anti-cutting and cracking performance in places with extremely high usage, this technical solution uses a mixed mud mainly composed of kaolinite instead of bauxite, and the mutual cooperation of washed mud and mixed mud is beneficial to improving the anti-cutting and cracking performance on the premise of realizing low-temperature and fast firing.

[0058] Furthermore, in the prior art, in order to improve the whiteness of products and reduce costs, yellow sand is usually added to the formula. However, the mineral composition of yellow sand is mainly free quartz. As a relatively sensitive crystal, free quartz is prone to phase transformation and accompanied by volume change during the cooling process of the rock slab, resulting in microcracks and affecting the anti-cutting crack performance. Therefore, in order to meet the usage scenarios with extremely high requirements for anti-cutting crack performance, in this technical solution, pyrophyllite with a higher whiteness is used to replace yellow sand. And as described above, the Al 2 O 3 and SiO 2 in pyrophyllite can react to form mullite crystals uniformly dispersed in the glass phase, which is beneficial to improving the anti-cutting crack performance.

[0059] Preferably, calculated by mass percentage, the chemical composition of the bentonite includes SiO 2 68 - 70%, Al 2 O 3 14.5 - 15%, Fe 2 O 3 0.8 - 0.9%, TiO 2 0.1 - 0.2%, CaO 1.4 - 1.6%, MgO 1.5 - 1.6%, K 2 O 2.9 - 3% and Na 2 O 1.6 - 1.7%, and the rest is loss on ignition.

[0060] This technical solution preferably adds magnesia soil with a CaO content of 0.7 - 0.8%, a MgO content of 19.5 - 20%, a K 2 O content of 0.2 - 0.3%, and a Na 2 O content of 0.2 - 0.3% calculated by mass percentage to the raw materials of the green body layer. This is beneficial to increasing the content of fluxes in the formula system on the premise of avoiding excessive fluxes in the formula causing the green body layer to be prone to softening and deformation during firing, so as to achieve the purpose of reducing the firing temperature and shortening the firing cycle. At the same time, the SiO 2 content in bentonite is as high as 68 - 70%, and the Al 2 O 3 content is 14.5 - 15%, which is beneficial to increasing the silicon content in the formula and thus improving the overall strength of the rock slab. In addition, it should be noted that bentonite is classified according to the content of Al 2 O 3 and SiO 2 and indeed belongs to the category of medium-aluminum and medium-silicon raw materials. However, the mineral composition of bentonite is mainly montmorillonite, which has a specific layered structure, making the Al 2 O 3 and SiO 2Combined tightly with specific chemical bonds and arrangements, resulting in the difficulty of separating and recombining Al in bentonite into mullite crystals during the sintering process. That is, although bentonite contains chemical components capable of reacting to form mullite, due to the particularity of its mineral composition and structure, it is difficult to form mullite crystals. 2 O 3 and SiO 2 It is difficult to separate and recombine into mullite crystals. That is, although bentonite contains chemical components that can react to form mullite, due to the particularity of its mineral composition and structure, it is difficult to form mullite crystals.

[0061] Preferably, calculated by mass percentage, the chemical composition of the bentonite includes SiO 2 68.45%, Al 2 O 3 14.57%, Fe 2 O 3 0.81%, TiO 2 0.11%, CaO 1.48%, MgO 1.59%, K 2 O 2.91%, Na 2 O 1.67%, and the rest is loss on ignition.

[0062] Further explanation, calculated by mass percentage, the chemical composition of the waste brick powder includes SiO 2 65 - 66%, Al 2 O 3 18 - 19%, Fe 2 O 3 1.7 - 1.8%, TiO 2 0.50 - 1%, CaO 0.5 - 0.7%, MgO 1.7 - 1.8%, K 2 O 1.9 - 2% and Na 2 O 2 - 2.1%, and the rest is loss on ignition;

[0063] The particle size of the waste brick powder ≤ 0.85mm.

[0064] This technical solution preferably adds waste brick powder with a CaO content of 0.5 - 0.7%, an MgO content of 1.7 - 1.8%, a K 2 O content of 1.9 - 2%, and a Na 2 O content of 2 - 2.1% calculated by mass percentage to the raw materials of the green body layer, which is beneficial to increasing the content of fluxes in the formula on the premise of avoiding excessive fluxes in the formula causing the green body layer to be prone to softening and deformation during firing, so as to achieve the purpose of reducing the firing temperature and shortening the firing cycle. At the same time, the SiO 2 content in the waste brick powder is as high as 65 - 66%, and the Al 2 O 3 content is as high as 18 - 19%, which is beneficial to increasing the content of silicon and aluminum in the formula, thereby improving the strength of the rock slab.

[0065] Furthermore, by limiting the particle size of waste brick powder, it is not only beneficial to improve its utilization rate, but also conducive to further optimizing the dispersibility of each phase in the waste brick powder, further promoting the uniform dispersion of mullite crystals in the glass phase, and further improving the anti-cutting and cracking performance of the rock slab. In addition, it can also ensure that the waste brick powder can better fill the micro-pores of the green body layer, enhance the compactness and strength of the rock slab, and is also beneficial to improving the anti-cutting and cracking performance of the rock slab.

[0066] Preferably, calculated by mass percentage, the chemical composition of the waste brick powder includes SiO 2 65.67%, Al 2 O 3 18.50%, Fe 2 O 3 1.75%, TiO 2 0.50%, CaO 0.62%, MgO 1.77%, K 2 O 1.92%, Na 2 O 2.09%, and the rest is loss on ignition.

[0067] Further illustration, calculated by mass percentage, the chemical composition of the pyrophyllite includes SiO 2 70 - 73%, Al 2 O 3 18 - 20%, Fe 2 O 3 0.5 - 0.8%, TiO 2 0.4 - 0.5%, CaO 0.2 - 0.3%, MgO 0.1 - 0.2%, K 2 O 2.3 - 2.4% and Na 2 O 0.1 - 0.2%, and the rest is loss on ignition.

[0068] This technical solution preferably adds pyrophyllite with a CaO content of 0.2 - 0.3%, an MgO content of 0.1 - 0.2%, a K 2 O content of 2.3 - 2.4%, and a Na 2 O content of 0.1 - 0.2% calculated by mass percentage to the raw materials of the green body layer, which is beneficial to increasing the content of flux in the formula on the premise of avoiding excessive flux in the formula causing the green body layer to be easily softened and deformed during the firing process, so as to achieve the purpose of reducing the firing temperature and shortening the firing cycle. At the same time, the SiO 2 content in pyrophyllite is as high as 70 - 73%, and the Al 2 O 3 content is as high as 18 - 20%, which is beneficial to increasing the content of silicon and aluminum in the formula, thereby improving the strength of the rock slab.

[0069] Preferably, calculated by mass percentage, the chemical composition of the pyrophyllite includes SiO 2 72.54%, Al 2 O 3 18.23%, Fe 2 O 3 0.79%, TiO 2 0.46%, CaO 0.24%, MgO 0.13%, K 2 O 2.31%, Na 2 O 0.16%, and the rest is loss on ignition.

[0070] Further illustration, calculated by mass percentage, the chemical composition of the albite includes SiO 2 68 - 70%, Al 2 O 3 16 - 18%, Fe 2 O 3 0.1 - 0.2%, TiO 2 0.05 - 0.1%, CaO 0.5 - 0.6%, MgO 0.1 - 0.2%, K 2 O 0.6 - 0.7% and Na 2 O 8 - 8.1%, and the rest is loss on ignition.

[0071] In this technical solution, preferably, the content of CaO calculated by mass percentage is 0.5 - 0.6%, the content of MgO is 0.1 - 0.2%, K 2 O's content is 0.6 - 0.7%, Na 2 O's content is 8 - 8.1% of albite is added to the raw materials of the green body layer, which is beneficial to increasing the content of fluxes in the formula on the premise of avoiding excessive fluxes in the formula causing the green body layer to be easily softened and deformed during firing, so as to achieve the purpose of reducing the firing temperature and shortening the firing cycle. At the same time, the content of SiO 2 in albite is as high as 68 - 70%, and the content of Al 2 O 3 is as high as 16 - 18%, which is beneficial to increasing the content of silicon and aluminum in the formula, thereby improving the strength of the rock slab.

[0072] Preferably, calculated by mass percentage, the chemical composition of the albite includes SiO 2 68.7%, Al 2 O 3 16.46%, Fe 2 O 3 0.19%, TiO 20.09%, CaO 0.54%, MgO 0.11%, K 2 O 0.66%, Na 2 O 8.01%, and the rest is loss on ignition.

[0073] Further explanation, calculated by mass percentage, the chemical composition of the mixed mud includes SiO 2 70 - 70.5%, Al 2 O 3 19 - 20%, Fe 2 O 3 1 - 1.2%, TiO 2 0.3 - 0.4%, CaO 0.4 - 0.5%, MgO 0.2 - 0.3%, K 2 O 1 - 1.1% and Na 2 O 0.2 - 0.3%, and the rest is loss on ignition.

[0074] This technical solution preferably adds the mixed mud with a CaO content of 0.4 - 0.5%, a MgO content of 0.2 - 0.3%, a K 2 O content of 1 - 1.1%, and a Na 2 O content of 0.2 - 0.3% calculated by mass percentage to the raw materials of the green body layer, which is beneficial to increasing the content of fluxes in the formula on the premise of avoiding excessive fluxes in the formula causing the green body layer to be prone to softening and deformation during firing, so as to achieve the purpose of reducing the firing temperature and shortening the firing cycle. At the same time, the SiO 2 content in the mixed mud is as high as 70 - 70.5%, and the Al 2 O 3 content is as high as 19 - 20%, which is beneficial to increasing the content of silicon and aluminum in the formula, thereby improving the strength of the rock slab.

[0075] Preferably, calculated by mass percentage, the chemical composition of the mixed mud includes SiO 2 70.09%, Al 2 O 3 19.07%, Fe 2 O 3 1.15%, TiO 2 0.39%, CaO 0.4%, MgO 0.24%, K 2 O 1.09%, Na 2 O 0.2%, and the rest is loss on ignition.

[0076] Further explanation, calculated by mass percentage, the chemical composition of the washed mud includes SiO 2 50 - 53%, Al 2 O 331 - 33%, Fe 2 O 3 1.4 - 1.5%, TiO 2 0.1 - 0.2%, CaO 0.1 - 0.2%, MgO 0.2 - 0.3%, K 2 O 3 - 3.2% and Na 2 O 0.3 - 0.4%, and the rest is loss on ignition.

[0077] This technical solution preferably calculates the content of SiO 2 by mass percentage to be 50 - 53% and Al 2 O 3 with a content of 31 - 33%, and the washed mud with kaolinite as the main mineral component is added to the raw materials of the green body layer, which is beneficial to the reaction of SiO 2 and Al 2 O 3 during calcination to generate mullite, increase the content of mullite and its distribution in the glass phase, thereby improving the anti - cutting crack performance and strength. It should be noted that the main mineral component of the washed mud is kaolinite.

[0078] Preferably, calculated by mass percentage, the chemical composition of the washed mud includes SiO 2 52.27%, Al 2 O 3 32.5%, Fe 2 O 3 1.41%, TiO 2 0.18%, CaO 0.12%, MgO 0.25%, K 2 O 3.16%, Na 2 O 0.37%, and the rest is loss on ignition.

[0079] Furthermore, calculated by mass percentage, the chemical composition of the magnesian soil includes SiO 2 62 - 63%, Al 2 O 3 5.7 - 5.8%, Fe 2 O 3 1.6 - 1.7%, TiO 2 0.1 - 0.2%, CaO 0.7 - 0.8%, MgO 19.5 - 20%, K 2 O 0.2 - 0.3% and Na 2 O 0.2 - 0.3%, and the rest is loss on ignition.

[0080] This technical solution preferably calculates the content of CaO by mass percentage to be 0.7 - 0.8%, the content of MgO to be 19.5 - 20%, K 2The content of O is 0.2 - 0.3%, Na 2 Adding magnesian soil with the content of O being 0.2 - 0.3% to the raw materials of the green body layer is beneficial to increasing the content of fluxes in the formula system on the premise of avoiding the excessive softening and deformation of the green body layer during firing caused by excessive fluxes in the formula, so as to achieve the purpose of reducing the firing temperature and shortening the firing cycle. At the same time, the content of SiO 2 in the magnesian soil is as high as 62 - 63%, which is beneficial to increasing the content of silicon and aluminum in the formula, thus facilitating the formation of more silicate crystals and further enhancing the overall strength of the rock slab. It should be noted that the mineral composition of the magnesian soil is mainly talc and free quartz, etc., and the component silicon dioxide in the magnesian soil mainly exists in the form of free quartz, and free quartz is difficult to react with other components. Therefore, adding magnesian soil to the formula does not tend to generate mullite crystals.

[0081] Preferably, calculated by mass percentage, the chemical composition of the magnesian soil includes SiO 2 62.585%, Al 2 O 3 5.79%, Fe 2 O 3 1.615%, TiO 2 0.13%, CaO 0.79%, MgO 19.5%, K 2 O 0.25%, Na 2 O 0.245%, and the rest is loss on ignition.

[0082] A preparation method of an anti-cutting and cracking rock slab for preparing the above anti-cutting and cracking rock slab, comprising the following steps:

[0083] A. Mix the formula amounts of bentonite, magnesian soil, waste brick powder, washed mud, pyrophyllite, albite and mixed mud evenly, then add water for ball milling and sieving to obtain a slurry; spray granulate the slurry to obtain a green body; press the green body into shape and dry it to obtain a green body layer; wherein, the fineness of the ball milling is 325 - mesh sieve, and calculated by mass percentage, the residue on sieve is 1.3 - 1.8%;

[0084] B. Apply a base glaze on the surface of the green body layer to obtain a base glaze layer;

[0085] C. Print color ink on the surface of the base glaze layer according to a preset pattern to obtain a decorative layer;

[0086] D. Apply a polished glaze on the surface of the decorative layer to obtain a polished glaze layer;

[0087] E. Dry and then fire in a kiln to obtain an anti-cutting and cracking rock slab; wherein, the firing temperature of the anti-cutting and cracking rock slab ≤ 1223 °C, and the firing cycle is 35 - 38 min.

[0088] The present technical solution also provides a method for preparing an anti-cutting and cracking rock slab. The preparation method is simple and highly operable, which is conducive to ensuring the relevant properties of the rock slab during the preparation process. It should be noted that the underglaze layer in the present technical solution is applied by the conventional underglaze in the ceramic field, the decorative layer is printed by the conventional color ink in the ceramic field, and the polishing glaze layer is applied by the conventional polishing glaze in the ceramic field. Therefore, the underglaze, color ink and polishing glaze will not be further described herein.

[0089] Specifically, when preparing the slurry in the present technical solution, the fineness of ball milling is limited to 325 mesh sieve, and the sieve residue is limited to 1.3-1.8%. By controlling the fineness of ball milling and the sieve residue, it is not only conducive to the smooth progress of the subsequent sieving operation, but also conducive to the more thorough chemical reaction of each raw material in the formula during the calcination process, so that the gaseous products are fully decomposed, and the generation of impurity phases and voids is effectively reduced. Thus, it is more conducive to the formation of a more uniform microstructure, and further improves the anti-cutting and cracking performance.

[0090] Further explanation, in step A, the specific method of sieving is as follows: the raw materials of the green body layer after ball milling with water are filtered successively through a 40-mesh sieve, a 60-mesh sieve, and an 80-mesh sieve once, and then filtered through an 110-mesh sieve twice.

[0091] The raw materials of the green body layer after ball milling with water contain particles of different particle sizes. Directly using an 110-mesh sieve for filtration is likely to cause the sieve to become blocked, affecting production efficiency. Therefore, the present technical solution adopts a hierarchical filtration strategy, specifically: using a 40-mesh sieve for filtration to remove coarse particles with a particle size greater than 0.364 mm; subsequently, using a 60-mesh sieve for further filtration to remove particles with a particle size greater than 0.245 mm; then, using an 80-mesh sieve for continuous filtration to remove particles with a particle size greater than 0.185 mm; finally, filtering through an 110-mesh sieve twice to ensure the removal of all particles with a particle size greater than 0.145 mm. The above series of filtration steps effectively reduce the content of coarse particles in the slurry, making the reaction of the green body layer more sufficient during the high-temperature firing process, avoiding the formation of defects or voids due to large particles, and thus reducing the generation of cracking points and improving the anti-cutting and cracking performance.

[0092] In addition, the reason for choosing to filter through an 110-mesh sieve twice is as follows: on the one hand, the sieve may be damaged imperceptibly during use. Although there are regular inspection measures, double filtration can further ensure that no particles are mixed in due to a damaged sieve; on the other hand, when the sieve mesh number exceeds 110 mesh, the filtration efficiency will decrease significantly, affecting the overall production capacity.

[0093] Further explanation, in step E, the firing curve of the anti-cutting and cracking rock slab includes a preheating section, a first pre-temperature section, a strong oxidation section, a second pre-temperature section, a medium-temperature section, a high-temperature section, a transition section, a rapid cooling section and a slow cooling section;

[0094] The top temperature of the preheating section rises from room temperature to 854 °C, and the bottom temperature rises from room temperature to 841 °C, taking 5 - 5.4 minutes;

[0095] The top temperature of the first preheating section rises from 854 °C to 927 °C, and the bottom temperature rises from 841 °C to 1018 °C, taking 0.7 - 0.9 minutes;

[0096] The top temperature of the strong oxidation section rises from 927 °C to 1105 °C, and the bottom temperature rises from 1018 °C to 1148 °C, taking 1.5 - 1.8 minutes;

[0097] The top temperature of the second preheating section drops from 1105 °C to 1030 °C and then rises from 1030 °C to 1080 °C, and the bottom temperature drops from 1148 °C to 1047 °C and then rises from 1047 °C to 1090 °C, taking 2.9 - 3 minutes;

[0098] The top temperature of the medium - temperature section rises from 1080 °C to 1194 °C, and the bottom temperature rises from 1090 °C to 1205 °C, taking 5.5 - 5.8 minutes;

[0099] The top temperature of the high - temperature section rises from 1194 °C to 1204 °C, and the bottom temperature rises from 1205 °C to 1223 °C, taking 4.5 - 5 minutes;

[0100] The top temperature of the transition section drops from 1204 °C to 950 °C, and the bottom temperature drops from 1223 °C to 950 °C, taking 2 - 2.1 minutes;

[0101] The top temperature of the rapid cooling section drops from 950 °C to 584 °C, and the bottom temperature drops from 950 °C to 586 °C, taking 2 - 2.5 minutes;

[0102] The top temperature of the slow cooling section drops from 584 °C to 97 °C, and the bottom temperature drops from 586 °C to 97 °C, taking 11 - 11.6 minutes.

[0103] This technical solution innovatively adds a strong oxidation section between the first preheating section and the second preheating section. The strong oxidation section uses high temperature to quickly burn the substances with high decomposition temperature (substances with decomposition temperature in the range of 1050 - 1100 °C) in the raw materials of the billet layer, effectively promoting the decomposition and discharge of the above - mentioned substances, thereby reducing their residues in the product, further reducing the porosity, avoiding stress concentration during cutting, and improving the anti - cutting crack performance. At the same time, the introduction of the strong oxidation section also helps to reduce the pores caused by the residues of substances such as carbonates and sulfates, further enhancing the anti - cutting crack performance.

[0104] Since the firing cycle is relatively fixed, if the sum of the time of the first pre-temperature stage, the strong oxidation stage and the second pre-temperature stage is too long, the medium temperature, high temperature stage and cooling stage will be shortened in disguise, thus affecting the quality of the product. Therefore, this technical solution strictly controls the total time of the first pre-temperature stage, the strong oxidation stage and the second pre-temperature stage to not exceed 7 minutes, thereby ensuring the various performances of the product under the premise of rapid firing.

[0105] In addition, this technical solution also optimizes the duration of the rapid cooling section and the slow cooling section. The rapid cooling section lasts more than 2 minutes, while the slow cooling section lasts more than 10 minutes, aiming to slow down the cooling rate, thereby reducing the phase change rate of free quartz in the green body layer, reducing microcracks caused by volume changes, and effectively improving the anti-cutting cracking performance.

[0106] Furthermore, due to the difference in shrinkage rates between the glaze layer (top layer) and the body layer (bottom layer) during the firing process, the rock slab is prone to concave or convex deformation. In addition, insufficient oxidation inside the body layer can easily lead to black heart oxidation, and black heart oxidation is usually related to the temperature distribution at the top and bottom of the pre-temperature section of the firing curve. Therefore, the present application limits the bottom temperature and top temperature of each stage in the firing curve, which is not only conducive to avoiding deformation of the calcined rock slab, thereby ensuring its flatness, but also helps to avoid black heart oxidation inside the rock slab and ensure its quality.

[0107] It is worth noting that the firing temperature of the rock slab refers to its maximum calcination temperature. Therefore, the firing temperature of the rock slab in this technical solution is as low as 1223°C. Compared with the traditional process, this firing temperature is lower, but it can still meet the product performance requirements.

[0108] The technical solution of the present invention is further illustrated below through specific implementation methods.

[0109] Performance Test:

[0110] Anti-cutting crack performance: Take 4 calcined rock slabs to obtain 4 rock slabs to be tested with a specification of 1500×750mm (i.e. length 1500mm, width 750mm). Cut the 4 rock slabs to be tested 10 times along the length direction, and the cutting interval is 10mm. If the 4 rock slabs to be tested do not have edge collapse during the cutting process, the anti-cutting crack performance is qualified.

[0111] Modulus of rupture: The modulus of rupture of the rock slab is tested in accordance with "GB / T 3810.4-2016 Test methods for ceramic tiles Part 4: Determination of modulus of rupture and breaking strength".

[0112] Destructive strength: The destructive strength of the rock slab is tested in accordance with "GB / T 3810.4-2016 Ceramic Tile Test Method Part 4: Determination of Rupture Modulus and Destructive Strength".

[0113] In the examples and comparative examples of the present invention, calculated by mass percentage, the chemical composition of waste brick powder includes SiO 2 65.67%, Al 2 O 3 18.50%, Fe 2 O 3 1.75%, TiO 2 0.50%, CaO 0.62%, MgO 1.77%, K 2 O 1.92%, Na 2 O 2.09%, and the rest is loss on ignition;

[0114] Calculated by mass percentage, the chemical composition of pyrophyllite includes SiO 2 72.54%, Al 2 O 3 18.23%, Fe 2 O 3 0.79%, TiO 2 0.46 %, CaO 0.24%, MgO 0.13%, K 2 O 2.31%, Na 2 O 0.16%, and the rest is loss on ignition;

[0115] Calculated by mass percentage, the chemical composition of albite includes SiO 2 68.7%, Al 2 O 3 16.46%, Fe 2 O 3 0.19%, TiO 2 0.09%, CaO 0.54%, MgO 0.11%, K 2 O 0.66%, Na 2 O 8.01%, and the rest is loss on ignition;

[0116] Calculated by mass percentage, the mineral composition of the mixed mud includes 60% kaolinite and 40% free quartz; and calculated by mass percentage, the chemical composition of the mixed mud includes SiO 2 70.09%, Al 2 O 3 19.07%, Fe 2 O 3 1.15%, TiO 2 0.39%, CaO 0.4%, MgO 0.24%, K 2 O 1.09%, Na 2 O 0.2%, and the rest is loss on ignition;

[0117] Calculated by mass percentage, the chemical composition of the washed mud includes SiO 2 52.27%, Al 2 O 3 32.5%, Fe 2 O 3 1.41%, TiO 2 0.18%, CaO 0.12%, MgO 0.25%, K 2 O 3.16%, Na 2 O 0.37%, and the rest is loss on ignition;

[0118] Calculated by mass percentage, the chemical composition of the magnesian soil includes SiO 2 62.585%, Al 2 O 3 5.79%, Fe 2 O 3 1.615%, TiO 2 0.13%, CaO 0.79%, MgO 19.5%, K 2 O 0.25%, Na 2 O 0.245%, and the rest is loss on ignition;

[0119] Calculated by mass percentage, the chemical composition of the bentonite includes SiO 2 68.45%, Al 2 O 3 14.57%, Fe 2 O 3 0.81%, TiO 2 0.11%, CaO 1.48%, MgO 1.59%, K 2 O 2.91%, Na 2 O 1.67%, and the rest is loss on ignition.

[0120] In addition, for those not specifying specific technologies or conditions in the examples and comparative examples, they shall be carried out according to the technologies or conditions described in the literature in this field or according to the product specifications. For reagents or instruments whose manufacturers are not specified, they are all conventional products that can be obtained through commercial purchase.

[0121] Example 1

[0122] A. Mix 1 part of bentonite, 4 parts of magnesian soil, 26 parts of waste brick powder with a particle size of 0.7 mm, 13 parts of washed mud, 30 parts of pyrophyllite, 14 parts of albite and 10 parts of mixed mud evenly, add water for ball milling and screening to obtain a slurry; spray granulate the slurry to obtain a green body; press and mold the green body and dry it to obtain a green body layer; among them, the fineness of ball milling is 325 mesh sieve, and calculated by mass percentage, the screen residue is 1.3%; the specific method of screening is: filter the raw materials of the green body layer after adding water for ball milling once with a 40-mesh screen, a 60-mesh screen, and an 80-mesh screen in sequence, and then filter twice with an 110-mesh screen;

[0123] B. Apply a base glaze on the surface of the green body layer to obtain a base glaze layer;

[0124] C. Print color ink on the surface of the base glaze layer according to a preset pattern to obtain a decorative layer;

[0125] D. Apply a polishing glaze on the surface of the decorative layer to obtain a polishing glaze layer;

[0126] E. Dry and then fire in a kiln to obtain a cut-resistant rock slab; among them, the firing curve of the cut-resistant rock slab includes a preheating section, a first pre-temperature section, a strong oxidation section, a second pre-temperature section, a medium temperature section, a high temperature section, a transition section, a rapid cooling section and a slow cooling section; the top temperature of the preheating section rises from room temperature to 854 °C, and the bottom temperature rises from room temperature to 841 °C, taking 5.41 min; the top temperature of the first pre-temperature section rises from 854 °C to 927 °C, and the bottom temperature rises from 841 °C to 1018 °C, taking 0.83 min; the top temperature of the strong oxidation section rises from 927 °C to 1105 °C, and the bottom temperature rises from 1018 °C to 1148 °C, taking 1.66 min; the top temperature of the second pre-temperature section drops from 1105 °C to 1030 °C, then rises from 1030 °C to 1080 °C, and the bottom temperature drops from 1148 °C to 1047 °C, then rises from 1047 °C to 1090 °C, taking 2.92 min; the top temperature of the medium temperature section rises from 1080 °C to 1194 °C, and the bottom temperature rises from 1090 °C to 1205 °C, taking 5.8 min; the top temperature of the high temperature section rises from 1194 °C to 1204 °C, and the bottom temperature rises from 1205 °C to 1223 °C, taking 4.99 min; the top temperature of the transition section drops from 1204 °C to 950 °C, and the bottom temperature drops from 1223 °C to 950 °C, taking 2.08 min; the top temperature of the rapid cooling section drops from 950 °C to 584 °C, and the bottom temperature drops from 950 °C to 586 °C, taking 2.5 min; the top temperature of the slow cooling section drops from 584 °C to 97 °C, and the bottom temperature drops from 586 °C to 97 °C, taking 11.6 min.

[0127] Example 2

[0128] A. Mix 2 parts of bentonite, 3 parts of magnesian soil, 22 parts of waste brick powder with a particle size of 0.8 mm, 15 parts of washed mud, 28 parts of pyrophyllite, 16 parts of albite and 10 parts of mixed mud evenly, add water for ball milling and screening to obtain a slurry; spray granulate the slurry to obtain a green body; press the green body into shape and dry it to obtain a green body layer; among them, the fineness of ball milling is 325 mesh sieve, and calculated by mass percentage, the screen residue is 1.5%; the specific method of screening is: filter the raw materials of the green body layer after adding water for ball milling successively through a 40-mesh screen, a 60-mesh screen, an 80-mesh screen once, and then filter through an 110-mesh screen twice;

[0129] B. Apply a base glaze on the surface of the green body layer to obtain a base glaze layer;

[0130] C. Print color ink on the surface of the base glaze layer according to a preset pattern to obtain a decorative layer;

[0131] D. Apply a polished glaze on the surface of the decorative layer to obtain a polished glaze layer;

[0132] E. Dry and then fire in a kiln to obtain a rock slab resistant to cutting and cracking; among them, the firing curve of the rock slab resistant to cutting and cracking includes a preheating section, a first pre-temperature section, a strong oxidation section, a second pre-temperature section, a medium temperature section, a high temperature section, a transition section, a rapid cooling section and a slow cooling section; the top temperature of the preheating section rises from room temperature to 854 °C, and the bottom temperature rises from room temperature to 841 °C, taking 5.2 min; the top temperature of the first pre-temperature section rises from 854 °C to 927 °C, and the bottom temperature rises from 841 °C to 1018 °C, taking 0.8 min; the top temperature of the strong oxidation section rises from 927 °C to 1105 °C, and the bottom temperature rises from 1018 °C to 1148 °C, taking 1.5 min; the top temperature of the second pre-temperature section drops from 1105 °C to 1030 °C, then rises from 1030 °C to 1080 °C, and the bottom temperature drops from 1148 °C to 1047 °C, then rises from 1047 °C to 1090 °C, taking 2.9 min; the top temperature of the medium temperature section rises from 1080 °C to 1194 °C, and the bottom temperature rises from 1090 °C to 1205 °C, taking 5.5 min; the top temperature of the high temperature section rises from 1194 °C to 1204 °C, and the bottom temperature rises from 1205 °C to 1223 °C, taking 4.5 min; the top temperature of the transition section drops from 1204 °C to 950 °C, and the bottom temperature drops from 1223 °C to 950 °C, taking 2 min; the top temperature of the rapid cooling section drops from 950 °C to 584 °C, and the bottom temperature drops from 950 °C to 586 °C, taking 2.5 min; the top temperature of the slow cooling section drops from 584 °C to 97 °C, and the bottom temperature drops from 586 °C to 97 °C, taking 11.2 min.

[0133] Example 3

[0134] A. Mix 3 parts of bentonite, 5 parts of magnesian soil, 28 parts of waste brick powder with a particle size of 0.6 mm, 14 parts of washed mud, 32 parts of pyrophyllite, 15 parts of albite and 9 parts of mixed mud evenly, add water for ball milling and sieving to obtain a slurry; spray granulate the slurry to obtain a green body; press the green body into shape and dry it to obtain a green body layer; among them, the fineness of ball milling is 325 mesh sieve, and calculated by mass percentage, the sieve residue is 1.4%; the specific method of sieving is: filter the raw materials of the green body layer after adding water for ball milling successively through a 40-mesh sieve, a 60-mesh sieve, an 80-mesh sieve once, and then filter through an 110-mesh sieve twice;

[0135] B. Apply a base glaze on the surface of the green body layer to obtain a base glaze layer;

[0136] C. Print color ink on the surface of the base glaze layer according to a preset pattern to obtain a decorative layer;

[0137] D. Apply a polished glaze on the surface of the decorative layer to obtain a polished glaze layer;

[0138] E. Dry and then fire in a kiln to obtain a cut-resistant rock slab; among them, the firing curve of the cut-resistant rock slab includes a preheating section, a first pre-temperature section, a strong oxidation section, a second pre-temperature section, a medium temperature section, a high temperature section, a transition section, a rapid cooling section and a slow cooling section; the top temperature of the preheating section rises from room temperature to 854 °C, and the bottom temperature rises from room temperature to 841 °C, taking 5.1 min; the top temperature of the first pre-temperature section rises from 854 °C to 927 °C, and the bottom temperature rises from 841 °C to 1018 °C, taking 0.75 min; the top temperature of the strong oxidation section rises from 927 °C to 1105 °C, and the bottom temperature rises from 1018 °C to 1148 °C, taking 1.5 min; the top temperature of the second pre-temperature section drops from 1105 °C to 1030 °C, then rises from 1030 °C to 1080 °C, and the bottom temperature drops from 1148 °C to 1047 °C, then rises from 1047 °C to 1090 °C, taking 2.95 min; the top temperature of the medium temperature section rises from 1080 °C to 1194 °C, and the bottom temperature rises from 1090 °C to 1205 °C, taking 5.6 min; the top temperature of the high temperature section rises from 1194 °C to 1204 °C, and the bottom temperature rises from 1205 °C to 1223 °C, taking 4.8 min; the top temperature of the transition section drops from 1204 °C to 950 °C, and the bottom temperature drops from 1223 °C to 950 °C, taking 2.1 min; the top temperature of the rapid cooling section drops from 950 °C to 584 °C, and the bottom temperature drops from 950 °C to 586 °C, taking 2.3 min; the top temperature of the slow cooling section drops from 584 °C to 97 °C, and the bottom temperature drops from 586 °C to 97 °C, taking 11.3 min.

[0139] Comparative Example 1

[0140] The preparation method and raw materials of Comparative Example 1 are the same as those of Example 1, except that no waste brick powder is added to the raw materials of the green body layer in Comparative Example 1.

[0141] Comparative Example 2

[0142] The preparation method and raw materials of Comparative Example 2 are the same as those of Example 1, except that pyrophyllite is not added to the raw materials of the green body layer in Comparative Example 2.

[0143] Comparative Example 3

[0144] The preparation method and raw materials of Comparative Example 3 are the same as those of Example 1, except that albite is not added to the raw materials of the green body layer in Comparative Example 3.

[0145] Comparative Example 4

[0146] The preparation method and raw materials of Comparative Example 4 are the same as those of Example 1, except that no mixed mud is added to the raw materials of the green body layer in Comparative Example 4.

[0147] The rock slabs were prepared by the preparation methods in the above-mentioned embodiments and comparative examples respectively, and the obtained rock slabs were tested for their anti-cutting cracking performance, rupture modulus and destructive strength. The results are shown in Table 1 below.

[0148] Table 1 Performance test results of different rock panels in the examples and comparative examples

[0149]

[0150] From the performance test results of each embodiment in the above table, it can be seen that the rock slab prepared by the preparation method of this scheme can be fired under the firing conditions of a firing temperature as low as 1223°C and a firing cycle of 35 to 38 minutes, and there is no edge collapse, and the rupture modulus is ≥54MPa, the destructive strength is ≥2500N, and it has high strength and resistance to cutting cracks.

[0151] Since no waste brick powder was added in Comparative Example 1, no pyrophyllite was added in Comparative Example 2, no albite was added in Comparative Example 3, and no mixed mud was added in Comparative Example 4, the fluxing effect of the above raw materials could not be exerted, so that the slab could not be completely calcined, and the obtained slab contained sandwich raw materials, which affected the reduction of the anti-cutting cracking performance. At the same time, it also led to a reduction in the amount of mullite crystals uniformly dispersed in the glass phase, further leading to a reduction in the anti-cutting cracking performance and strength of the slab.

[0152] The technical principle of the present invention is described above in conjunction with specific embodiments. These descriptions are only for explaining the principle of the present invention and cannot be interpreted as limiting the scope of protection of the present invention in any way. Based on the explanations herein, those skilled in the art can associate other specific implementations of the present invention without paying creative labor, and these methods will fall within the scope of protection of the present invention.

Claims

1. A cutting and cracking resistant rock plate, characterized in that: It includes a body layer, a base glaze layer, a decorative layer and a polishing glaze layer which are arranged in sequence from bottom to top; Calculated by weight, the green body layer is composed of the following raw materials: 1-3 parts of bentonite, 3-5 parts of magnesia clay, 22-28 parts of waste brick powder, 11-15 parts of washed mud, 28-35 parts of pyrophyllite, 12-16 parts of albite and 8-12 parts of mixed mud; The chemical compositions of the waste brick powder, the pyrophyllite, the albite and the mixed mud all include SiO2, Al2O3, Fe2O3, TiO2, CaO, MgO and K2O; Calculated by mass percentage, the content of SiO2 in the waste brick powder, the pyrophyllite, the albite and the mixed mud is 65-75%, and the content of Al2O3 is 13-20%; Calculated by mass percentage, the mineral components of the mixed mud include 50-60% kaolinite and 40-50% free quartz; The firing curve of the anti-cutting and cracking rock plate includes a preheating section, a first pre-temperature section, a strong oxidation section, a second pre-temperature section, a medium temperature section, a high temperature section, a transition section, a rapid cooling section and a slow cooling section; The top temperature of the preheating section rises from room temperature to 854°C, and the bottom temperature rises from room temperature to 841°C, which takes 5 to 5.4 minutes; The top temperature of the first pre-temperature section increased from 854°C to 927°C, and the bottom temperature increased from 841°C to 1018°C, which took 0.7 to 0.9 minutes; The top temperature of the strong oxidation section increased from 927°C to 1105°C, and the bottom temperature increased from 1018°C to 1148°C, which took 1.5 to 1.8 minutes; The top temperature of the second front temperature section dropped from 1105°C to 1030°C, and then increased from 1030°C to 1080°C, and the bottom temperature dropped from 1148°C to 1047°C, and then increased from 1047°C to 1090°C, which took 2.9 to 3 minutes; The top temperature of the medium temperature section rises from 1080°C to 1194°C, and the bottom temperature rises from 1090°C to 1205°C, which takes 5.5 to 5.8 minutes; The top temperature of the high temperature section increased from 1194°C to 1204°C, and the bottom temperature increased from 1205°C to 1223°C, which took 4.5 to 5 minutes; The top temperature of the transition section drops from 1204°C to 950°C, and the bottom temperature drops from 1223°C to 950°C, which takes 2 to 2.1 minutes; The top temperature of the quenching section drops from 950°C to 584°C, and the bottom temperature drops from 950°C to 586°C, which takes 2 to 2.5 minutes; The top temperature of the slow cooling section dropped from 584° C. to 97° C., and the bottom temperature dropped from 586° C. to 97° C., which took 11 to 11.6 minutes.

2. The anti-cutting rock cracking plate according to claim 1, characterized in that: Calculated by mass percentage, the chemical composition of the waste brick powder includes SiO2 65-66%, Al2O3 18-19%, Fe2O3 1.7-1.8%, TiO2 0.50-1%, CaO 0.5-0.7%, MgO 1.7-1.8%, K2O 1.9-2% and Na2O 2-2.1%, and the rest is loss on ignition; The particle size of the waste brick powder is ≤0.85 mm.

3. The anti-cutting rock cracking plate according to claim 1, characterized in that: Calculated by mass percentage, the chemical composition of the pyrophyllite includes SiO2 70-73%, Al2O3 18-20%, Fe2O3 0.5-0.8%, TiO2 0.4-0.5%, CaO 0.2-0.3%, MgO 0.1-0.2%, K2O 2.3-2.4% and Na2O 0.1-0.2%, and the rest is loss on ignition.

4. The anti-cutting rock cracking plate according to claim 1, characterized in that: Calculated by mass percentage, the chemical composition of the albite includes SiO2 68-70%, Al2O3 16-18%, Fe2O3 0.1-0.2%, TiO2 0.05-0.1%, CaO 0.5-0.6%, MgO 0.1-0.2%, K2O 0.6-0.7% and Na2O 8-8.1%, and the rest is loss on ignition.

5. The anti-cutting rock cracking plate according to claim 1, characterized in that: Calculated by mass percentage, the chemical composition of the mixed mud includes SiO2 70-70.5%, Al2O3 19-20%, Fe2O3 1-1.2%, TiO2 0.3-0.4%, CaO 0.4-0.5%, MgO 0.2-0.3%, K2O 1-1.1% and Na2O 0.2-0.3%, and the rest is loss on ignition.

6. The anti-cutting rock cracking plate according to claim 1, characterized in that: Calculated by mass percentage, the chemical composition of the washed mud includes SiO2 50-53%, Al2O3 31-33%, Fe2O3 1.4-1.5%, TiO2 0.1-0.2%, CaO 0.1-0.2%, MgO 0.2-0.3%, K2O 3-3.2% and Na2O 0.3-0.4%, and the rest is loss on ignition.

7. The anti-cutting rock cracking plate according to claim 1, characterized in that: Calculated by mass percentage, the chemical composition of the magnesia soil includes SiO2 62-63%, Al2O3 5.7-5.8%, Fe2O3 1.6-1.7%, TiO2 0.1-0.2%, CaO 0.7-0.8%, MgO 19.5-20%, K2O 0.2-0.3% and Na2O 0.2-0.3%, and the rest is loss on ignition.

8. A method for preparing a cutting-resistant rock plate, characterized in that: The method for preparing the anti-cutting rock cracking board according to any one of claims 1 to 7 comprises the following steps: A. After mixing the formulated amount of bentonite, magnesia clay, waste brick powder, washed mud, pyrophyllite, albite and mixed mud evenly, adding water to ball mill and sieving to obtain slurry; spray granulating the slurry to obtain a blank; pressing the blank into shape, and drying to obtain a blank layer; wherein the fineness of the ball mill is a 325 mesh sieve, and the sieve residue is 1.3-1.8% calculated by mass percentage; B. Applying base glaze on the surface of the body layer to obtain a base glaze layer; C. Printing color ink on the surface of the base glaze layer according to a preset pattern to obtain a decorative layer; D. Apply glaze on the surface of the decorative layer to obtain a glaze layer; E. After drying, the slab is put into a kiln for firing to obtain a cutting-resistant rock board; wherein the firing temperature of the cutting-resistant rock board is ≤1223°C, and the firing cycle is 35 to 38 minutes.

9. The method for preparing a cutting-resistant rock plate according to claim 8, characterized in that: In step A, the specific method of screening is: filtering the raw material of the green body layer after water ball milling through a 40-mesh sieve, a 60-mesh sieve, and an 80-mesh sieve in sequence, and then filtering twice through a 110-mesh sieve.

10. The method for preparing a cutting-resistant rock plate according to claim 8, characterized in that: In step E, the firing curve of the anti-cutting and cracking rock plate includes a preheating section, a first pre-temperature section, a strong oxidation section, a second pre-temperature section, a medium temperature section, a high temperature section, a transition section, a rapid cooling section and a slow cooling section; The top temperature of the preheating section rises from room temperature to 854°C, and the bottom temperature rises from room temperature to 841°C, which takes 5 to 5.4 minutes; The top temperature of the first pre-temperature section increased from 854°C to 927°C, and the bottom temperature increased from 841°C to 1018°C, which took 0.7 to 0.9 minutes; The top temperature of the strong oxidation section increased from 927°C to 1105°C, and the bottom temperature increased from 1018°C to 1148°C, which took 1.5 to 1.8 minutes; The top temperature of the second front temperature section dropped from 1105°C to 1030°C, and then increased from 1030°C to 1080°C, and the bottom temperature dropped from 1148°C to 1047°C, and then increased from 1047°C to 1090°C, which took 2.9 to 3 minutes; The top temperature of the medium temperature section rises from 1080°C to 1194°C, and the bottom temperature rises from 1090°C to 1205°C, which takes 5.5 to 5.8 minutes; The top temperature of the high temperature section increased from 1194°C to 1204°C, and the bottom temperature increased from 1205°C to 1223°C, which took 4.5 to 5 minutes; The top temperature of the transition section drops from 1204°C to 950°C, and the bottom temperature drops from 1223°C to 950°C, which takes 2 to 2.1 minutes; The top temperature of the quenching section drops from 950°C to 584°C, and the bottom temperature drops from 950°C to 586°C, which takes 2 to 2.5 minutes; The top temperature of the slow cooling section dropped from 584° C. to 97° C., and the bottom temperature dropped from 586° C. to 97° C., which took 11 to 11.6 minutes.

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