True wear-resistant ceramic tile and preparation method thereof

Abstract

The invention discloses a real wear-resistant ceramic tile and a preparation method thereof, and belongs to the technical field of ceramic tile preparation. The preparation method comprises the following steps: glazing wear-resistant glaze slip on the surface of a ceramic body by a glaze scraper, controlling the glazing thickness to be 0.5-0.7 mm, then drying at 130-150 DEG C for 30 minutes, and then calcining at 1180-1240 DEG C for 1.5-2 hours to obtain the ceramic tile. According to the invention, the wear-resistant glaze slip prepared from the organic silicon modified dispersant and the mixed mineral powder is glazed on the surface of the ceramic green body, so that good hardness, wear resistance and low water absorption are realized.

Description

Technical Field

[0001] The present invention belongs to the technical field of tile preparation, and particularly relates to a true wear-resistant ceramic tile and a preparation method thereof. Background Art

[0002] China is not only a large producer of tiles but also a large consumer of tiles. As a key building decoration material, tiles play an important role in the decoration of residential houses, office buildings and other architectural houses. Ceramic tiles are a kind of building material widely used in the decoration of walls and floors. It is mainly made of natural minerals such as clay, quartz, feldspar, etc., and is processed through processes such as molding and firing. Due to its beautiful appearance, durability, easy cleaning and other characteristics, ceramic tiles occupy an important position in modern architecture. The quality of the tile glaze directly affects the beauty and performance of the tile. For example, if there are fine cracks in the tile glaze, its waterproof performance will surely be affected. For most consumers, the quality of the tile glaze often becomes an important reference index for whether to purchase. Therefore, if there are problems with the tile glaze quality, it usually brings very adverse effects to the product. The polished glazed tiles in ceramic tile products have the characteristics of a smooth and transparent surface and a rich variety of background colors with textures after a unique polishing process. However, the surface wear resistance of general polished glazed tiles is very low, and it is very easy to be damaged during the wear process, which will have an adverse impact on the brightness, color and surface texture. And during transportation, the collision between tiles is also very easy to form scratches, resulting in transportation losses.

[0003] To solve the wear resistance problem of polished glazed tiles, improving the mechanical strength and wear resistance of the glaze has been the main research direction in recent years. Abrasive wear is one of the most common wear mechanisms on the surface of ceramic materials. It is mainly defined as a kind of wear caused by the migration of materials due to hard particles or hard protrusions, which refers to the phenomenon of surface material loss caused by the mutual friction between the object surface and hard particles or hard protrusions. Among them, pulling and cracking can strongly reduce the mechanical properties, especially hardness and wear resistance, and will also cause deterioration of aesthetics, brightness and color, and material loss. In addition, the areas with cracks and material removal increase the surface roughness, which is convenient for the attachment of powder and other dirt and is difficult to clean.

[0004] Patent CN115745568A discloses a wear-resistant ceramic tile and a preparation method thereof. The invention improves the mechanical strength of the green body by adding raw materials such as strontium carbonate, cerium oxide and calcium phosphate to the green body; improves the hardness and wear resistance of the surface glaze by adding raw materials such as zirconium silicate and silicon nitride to the surface glaze layer; improves the wear resistance and anti-slip performance of the wear-resistant layer by adding raw materials such as zinc oxide whiskers, magnesium borate whiskers, aluminum nitride and titanium diboride to the wear-resistant layer, and appropriately proportioning the green body, surface glaze and wear-resistant layer, so as to produce a synergistic effect, making the prepared ceramic tile have high surface wear strength and friction coefficient, and having good wear resistance and anti-slip performance.

[0005] Patent CN113999055A discloses an anti-fouling and wear-resistant ceramic tile and its preparation method. In this invention, wear-resistant particles are prepared by mixing oxides such as alumina, silica, calcium oxide, zirconium oxide, titanium oxide, and lanthanum oxide, and then an anti-fouling and wear-resistant ceramic tile is prepared.

[0006] The above improvement is mainly achieved by adding wear-resistant inorganic oxides to prepare a glaze, which is then applied to the surface of the ceramic tile body and fired at high temperature to obtain a ceramic tile with good wear resistance. However, due to the large difference in the thermal expansion coefficients between different inorganic oxides, the glaze surface may crack and peel off, affecting the hardness performance of the ceramic tile.

[0007] Therefore, it is of great significance to develop a new method to improve the surface wear resistance of ceramic tiles. Summary of the Invention

[0008] In view of the deficiencies of the prior art, in this invention, the prepared wear-resistant glaze slurry is applied to the surface of the ceramic blank, and then fired at high temperature to obtain a ceramic tile with good wear resistance, thus solving the technical problems raised in the background art. Specifically, the technical solution of this invention includes the following: A true wear-resistant ceramic tile, which is composed of a ceramic body and a wear-resistant glaze slurry.

[0009] Further, the preparation method of the ceramic body includes the steps of: Quartz, kaolin, glass powder, ceramic waste, and plagioclase are mixed and crushed in a weight ratio of 1-2:19-25:11-14:17-20:3-6 to obtain a crushed material. The crushed material, water, and grinding beads are mixed and wet-ground in a weight ratio of 1:1:2 to obtain a body slurry; The body slurry and a binder are mixed and atomized granulated in a weight ratio of 10:0.2-0.3 to obtain a body powder. After being pressed into shape, the body powder is dried to obtain a ceramic body.

[0010] Further, the binder includes polyvinyl alcohol.

[0011] Further, the preparation method of the wear-resistant glaze slurry includes the following steps: White fused alumina, mullite, glass fiber, zirconium silicate, and wollastonite are mixed and crushed in a weight ratio of 15-18:8-11:1-4:2-3:6-12 to obtain a crushed ore material. The crushed ore material and grinding beads are mixed and dry-ground in a weight ratio of 1:2.5 and sieved to obtain a mixed mineral powder; 5-8 parts by weight of the mixed mineral powder, 0.08-0.1 part by weight of an organosilicon-modified dispersant, and 2-4 parts by weight of water are weighed and mixed and stirred and aged in a weight ratio of 5-8:0.08-0.1:2-4 to obtain a wear-resistant glaze slurry.

[0012] Further, the preparation method of the silicone-modified dispersant comprises the following steps: A silane coupling agent, an ethanol-aqueous solution, and a dispersant are mixed and stirred in a weight ratio of 1:95-100:10-12 to obtain a mixed solution. After adjusting the pH of the mixed solution to 6.0-6.5, it is subjected to a heat preservation reaction to obtain the silicone-modified dispersant.

[0013] Further, the silane coupling agent includes γ-aminopropyltrimethoxysilane or γ-aminopropyltriethoxysilane.

[0014] Further, the ethanol-aqueous solution is composed of anhydrous ethanol and deionized water mixed in a weight ratio of 1:7-9.

[0015] Further, the dispersant includes sodium lignosulfonate.

[0016] Further, the conditions of the heat preservation reaction include a reaction temperature of 30°C-40°C and a reaction time of 4h-6h.

[0017] A preparation method of a true wear-resistant ceramic tile, the preparation method comprising the following steps: The wear-resistant glaze slurry is applied to the surface of the ceramic body by a glazing tool, and the glazing thickness is controlled to be 0.5mm-0.7mm. Then, it is first dried at 130°C-150°C for 30min, and then calcined at 1180°C-1240°C for 1.5h-2h to obtain the ceramic tile.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention uses white corundum, mullite, glass fiber, zirconium silicate, and wollastonite as raw materials for preparing the wear-resistant glaze slurry. The thermal expansion coefficients of white corundum, mullite, glass fiber, zirconium silicate, and wollastonite are relatively low, which can reduce the adverse effects of cracking caused by expansion during high-temperature calcination. Then, they are mixed, ground, and sieved to obtain a mixed mineral powder with a certain particle size. The reduction of the particle size helps to reduce the formation of pores during high-temperature calcination, preventing the increase in water absorption and the influence on the hardness of the ceramic tile caused by excessive pores. However, it is found in the experiment that simply mixing after grinding, the hardness of the finally prepared ceramic tile is relatively poor. By adding a silicone-modified dispersant, the finer mixed mineral powder can be evenly dispersed when preparing the wear-resistant glaze slurry, reducing agglomeration. The silicone-modified dispersant can not only disperse the mixed mineral powder and reduce the use of water, reducing the adverse effects of glaze surface cracking caused by pores generated during high-temperature calcination, but also complex metal ions in the inorganic mineral material through the carboxyl group in its structure, further increasing the surface hardness of the ceramic tile. Moreover, compared with ordinary sodium lignosulfonate, the silicone-modified dispersant can resist the rapid decomposition of sodium lignosulfonate due to the high temperature in the heating stage, thus losing its function of improving the glaze surface performance of the ceramic tile. Detailed implementation mode

[0019] Next, through the embodiments of the present invention, the technical solutions of the present invention will be clearly and completely described. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work belong to the scope of protection of the present invention.

[0020] Unless otherwise specified, the raw materials and reagents used in the present invention below are all commercially available products or can be prepared by known methods.

[0021] The ceramic waste comes from Shandong Hemusen New Materials Co., Ltd.

[0022] Preparation Example 1: A method for preparing a ceramic green body specifically includes the following process: Weigh 1 part by weight of quartz, 19 parts by weight of kaolin, 11 parts by weight of glass powder, 17 parts by weight of ceramic waste, and 3 parts by weight of plagioclase, mix them in a crusher for crushing treatment, add the crushed material obtained by passing through a 50-mesh sieve after the crushing treatment and water to a ball mill together, and control the weight ratio of the crushed material: water: grinding beads to be 1:1:2. Mix and wet grind for 10 minutes to obtain a green body slurry. Weigh 10 parts by weight of the green body slurry and 0.2 parts by weight of polyvinyl alcohol, mix and stir, and then atomize and granulate to obtain a green body powder. The green body powder is sent to a press for molding, and then dried at 55°C for 5 hours to obtain a ceramic green body.

[0023] Preparation Example 2: A method for preparing a ceramic green body specifically includes the following process: Weigh 1 part by weight of quartz, 21 parts by weight of kaolin, 12 parts by weight of glass powder, 18 parts by weight of ceramic waste, and 4 parts by weight of plagioclase, mix them in a crusher for crushing treatment, add the crushed material obtained by passing through a 50-mesh sieve after the crushing treatment and water to a ball mill together, and control the weight ratio of the crushed material: water: grinding beads to be 1:1:2. Mix and wet grind for 10 minutes to obtain a green body slurry. Weigh 10 parts by weight of the green body slurry and 0.2 parts by weight of polyvinyl alcohol, mix and stir, and then atomize and granulate to obtain a green body powder. The green body powder is sent to a press for molding, and then dried at 55°C for 5 hours to obtain a ceramic green body.

[0024] Preparation Example 3: A method for preparing a ceramic green body specifically includes the following process: Weigh 2 parts by weight of quartz, 23 parts by weight of kaolin, 13 parts by weight of glass powder, 19 parts by weight of ceramic waste, and 5 parts by weight of plagioclase, mix them in a crusher for crushing treatment. Add the crushed material obtained by passing through a 50-mesh sieve after the crushing treatment and water together into a ball mill. Control the weight ratio of the crushed material: water: grinding beads to be 1:1:2, and wet-mix for 10 min to obtain a green body slurry. Weigh 10 parts by weight of the green body slurry and 0.3 parts by weight of polyvinyl alcohol, mix and stir them, and then atomize and granulate to obtain a green body powder. Feed the green body powder into a press for molding, and then dry it at 55 °C for 5 h to obtain a ceramic green body.

[0025] Preparation Example 4: A method for preparing a ceramic green body, specifically including the following process: Weigh 2 parts by weight of quartz, 25 parts by weight of kaolin, 14 parts by weight of glass powder, 20 parts by weight of ceramic waste, and 6 parts by weight of plagioclase, mix them in a crusher for crushing treatment. Add the crushed material obtained by passing through a 50-mesh sieve after the crushing treatment and water together into a ball mill. Control the weight ratio of the crushed material: water: grinding beads to be 1:1:2, and wet-mix for 10 min to obtain a green body slurry. Weigh 10 parts by weight of the green body slurry and 0.3 parts by weight of polyvinyl alcohol, mix and stir them, and then atomize and granulate to obtain a green body powder. Feed the green body powder into a press for molding, and then dry it at 55 °C for 5 h to obtain a ceramic green body.

[0026] Preparation Example 5: A method for preparing a ceramic green body, specifically including the following process: Weigh 5 parts by weight of quartz, 25 parts by weight of kaolin, 14 parts by weight of glass powder, 20 parts by weight of ceramic waste, and 6 parts by weight of plagioclase, mix them in a crusher for crushing treatment. Add the crushed material obtained by passing through a 50-mesh sieve after the crushing treatment and water together into a ball mill. Control the weight ratio of the crushed material: water: grinding beads to be 1:1:2, and wet-mix for 10 min to obtain a green body slurry. Weigh 10 parts by weight of the green body slurry and 0.3 parts by weight of polyvinyl alcohol, mix and stir them, and then atomize and granulate to obtain a green body powder. Feed the green body powder into a press for molding, and then dry it at 55 °C for 5 h to obtain a ceramic green body.

[0027] Preparation Example 6: A method for preparing a ceramic green body, specifically including the following process: Weigh 2 parts by weight of quartz, 25 parts by weight of kaolin, 14 parts by weight of glass powder, 20 parts by weight of ceramic waste and 6 parts by weight of plagioclase, mix them in a crusher for crushing treatment, add the crushed material obtained by passing through a 50-mesh sieve after crushing treatment and water into a ball mill together, and control the weight ratio of the crushed material: water: grinding beads to be 1:1:2. Wet-mix for 10 min to obtain a green body slurry. Weigh 10 parts by weight of the green body slurry and 0.5 part by weight of polyvinyl alcohol, mix and stir them, and then atomize and granulate to obtain a green body powder. The green body powder is sent to a press for molding, and then dried at 55 °C for 5 h to obtain a ceramic green body.

[0028] Preparation Example 7: A preparation method of an organosilicon-modified dispersant specifically includes the following process: Disperse 1 part by weight of γ-aminopropyltrimethoxysilane in 95 parts by weight of an ethanol-water solution (obtained by mixing 1 part by weight of absolute ethanol and 7 parts by weight of deionized water and stirring), then add 10 parts by weight of a lignosulfonate dispersant and mix and stir to obtain a mixed solution. Adjust the pH value of the mixed solution to 6.0 with dilute hydrochloric acid, and then place it in a water bath at 30 °C and stir and react at a rotation speed of 200 r / min for 4 h. After the reaction is completed, pour the reaction solution into a dialysis bag with a cut-off molecular weight of 500 Da, and perform dialysis treatment with distilled water for 60 h to obtain the organosilicon-modified dispersant.

[0029] Preparation Example 8: A preparation method of an organosilicon-modified dispersant specifically includes the following process: Disperse 1 part by weight of γ-aminopropyltrimethoxysilane in 96 parts by weight of an ethanol-water solution (obtained by mixing 1 part by weight of absolute ethanol and 8 parts by weight of deionized water and stirring), then add 11 parts by weight of a lignosulfonate dispersant and mix and stir to obtain a mixed solution. Adjust the pH value of the mixed solution to 6.0 with dilute hydrochloric acid, and then place it in a water bath at 35 °C and stir and react at a rotation speed of 200 r / min for 5 h. After the reaction is completed, pour the reaction solution into a dialysis bag with a cut-off molecular weight of 500 Da, and perform dialysis treatment with distilled water for 60 h to obtain the organosilicon-modified dispersant.

[0030] Preparation Example 9: A preparation method of an organosilicon-modified dispersant specifically includes the following process: Disperse 1 part by weight of γ-aminopropyltriethoxysilane in 98 parts by weight of an ethanol-water solution (obtained by mixing 1 part by weight of absolute ethanol and 9 parts by weight of deionized water and stirring), then add 11 parts by weight of a lignosulfonate dispersant and mix and stir to obtain a mixed solution. Adjust the pH value of the mixed solution to 6.5 with dilute hydrochloric acid, and then place it in a water bath at 35 °C and stir and react at a rotation speed of 200 r / min for 5 h. After the reaction is completed, pour the reaction solution into a dialysis bag with a cut-off molecular weight of 500 Da, and perform dialysis treatment with distilled water for 60 h to obtain the organosilicon-modified dispersant.

[0031] Preparation Example 10: A method for preparing an organosilicon-modified dispersant, specifically including the following process: Disperse 1 part by weight of γ-aminopropyltriethoxysilane in 100 parts by weight of an ethanol-aqueous solution (obtained by mixing and stirring 1 part by weight of absolute ethanol and 9 parts by weight of deionized water), then add 12 parts by weight of a lignosulfonate dispersant and mix and stir to obtain a mixed solution. Adjust the pH value of the mixed solution to 6.5 with dilute hydrochloric acid, and then place it in a water bath at 40 °C and stir and react at a speed of 200 r / min for 6 h. After the reaction is completed, pour the reaction solution into a dialysis bag with a molecular weight cut-off of 500 Da and dialyze it with distilled water for 60 h to obtain the organosilicon-modified dispersant.

[0032] Preparation Example 11: A method for preparing an organosilicon-modified dispersant, specifically including the following process: Disperse 1 part by weight of vinyltriethoxysilane in 100 parts by weight of an ethanol-aqueous solution (obtained by mixing and stirring 1 part by weight of absolute ethanol and 9 parts by weight of deionized water), then add 12 parts by weight of a lignosulfonate dispersant and mix and stir to obtain a mixed solution. Adjust the pH value of the mixed solution to 6.5 with dilute hydrochloric acid, and then place it in a water bath at 40 °C and stir and react at a speed of 200 r / min for 6 h. After the reaction is completed, pour the reaction solution into a dialysis bag with a molecular weight cut-off of 500 Da and dialyze it with distilled water for 60 h to obtain the organosilicon-modified dispersant.

[0033] Preparation Example 12: A method for preparing an organosilicon-modified dispersant, specifically including the following process: Disperse 1 part by weight of γ-aminopropyltriethoxysilane in 100 parts by weight of an ethanol-aqueous solution (obtained by mixing and stirring 1 part by weight of absolute ethanol and 9 parts by weight of deionized water), then add 12 parts by weight of a sulfonated melamine formaldehyde dispersant and mix and stir to obtain a mixed solution. Adjust the pH value of the mixed solution to 6.5 with dilute hydrochloric acid, and then place it in a water bath at 40 °C and stir and react at a speed of 200 r / min for 6 h. After the reaction is completed, pour the reaction solution into a dialysis bag with a molecular weight cut-off of 500 Da and dialyze it with distilled water for 60 h to obtain the organosilicon-modified dispersant.

[0034] Preparation Example 13: A method for preparing a wear-resistant glaze slurry, specifically including the following process: Weigh 15 parts by weight of white fused alumina, 8 parts by weight of mullite, 1 part by weight of glass fiber, 2 parts by weight of zirconium silicate and 6 parts by weight of wollastonite, mix them in a crusher for crushing treatment, add the crushed ore obtained after the crushing treatment to a ball mill, control the weight ratio of the crushed ore to the grinding beads to be 1:2.5, mix and dry grind at a speed of 400 r / min for 80 min, and pass through a 500-mesh sieve after the dry grinding to obtain a mixed mineral powder. Weigh 5 parts by weight of the mixed mineral powder, 0.08 part by weight of the organosilicon-modified dispersant obtained in Preparation Example 7 and 2 parts by weight of water, mix and stir for 1 h, and then age for 2 days to obtain the wear-resistant glaze slurry.

[0035] Preparation Example 14: A method for preparing a wear-resistant glaze slurry, specifically including the following process: Weigh 16 parts by weight of white fused alumina, 9 parts by weight of mullite, 2 parts by weight of glass fiber, 2 parts by weight of zirconium silicate and 8 parts by weight of wollastonite, mix them in a crusher for crushing treatment, add the crushed ore obtained after the crushing treatment to a ball mill, control the weight ratio of the crushed ore to the grinding beads to be 1:2.5, mix and dry grind at a speed of 400 r / min for 85 min, and pass through a 500-mesh sieve after the dry grinding to obtain a mixed mineral powder. Weigh 6 parts by weight of the mixed mineral powder, 0.09 part by weight of the organosilicon-modified dispersant obtained in Preparation Example 8 and 3 parts by weight of water, mix and stir for 1 h, and then age for 2 days to obtain the wear-resistant glaze slurry.

[0036] Preparation Example 15: A method for preparing a wear-resistant glaze slurry, specifically including the following process: Weigh 17 parts by weight of white fused alumina, 10 parts by weight of mullite, 3 parts by weight of glass fiber, 3 parts by weight of zirconium silicate and 10 parts by weight of wollastonite, mix them in a crusher for crushing treatment, add the crushed ore obtained after the crushing treatment to a ball mill, control the weight ratio of the crushed ore to the grinding beads to be 1:2.5, mix and dry grind at a speed of 400 r / min for 85 min, and pass through a 500-mesh sieve after the dry grinding to obtain a mixed mineral powder. Weigh 7 parts by weight of the mixed mineral powder, 0.1 part by weight of the organosilicon-modified dispersant obtained in Preparation Example 9 and 3 parts by weight of water, mix and stir for 2 h, and then age for 3 days to obtain the wear-resistant glaze slurry.

[0037] Preparation Example 16: A method for preparing a wear-resistant glaze slurry, specifically including the following process: Weigh 18 parts by weight of white fused alumina, 11 parts by weight of mullite, 4 parts by weight of glass fiber, 3 parts by weight of zirconium silicate and 12 parts by weight of wollastonite, mix them and conduct crushing treatment in a crusher. Add the crushed ore obtained after the crushing treatment to a ball mill, control the weight ratio of the crushed ore to the grinding beads to 1:2.5, mix and dry grind at a speed of 400 r / min for 90 min. After the dry grinding is completed, pass through a 500-mesh sieve to obtain a mixed mineral powder. Weigh 8 parts by weight of the mixed mineral powder, 0.1 part by weight of the organosilicon-modified dispersant obtained in Preparation Example 10 and 4 parts by weight of water, mix and stir for 2 h, and then age for 3 days to obtain the wear-resistant glaze slurry.

[0038] Preparation Example 17: A method for preparing a wear-resistant glaze slurry, specifically including the following process: Weigh 18 parts by weight of white fused alumina, 11 parts by weight of mullite, 4 parts by weight of glass fiber, 3 parts by weight of zirconium silicate and 12 parts by weight of wollastonite, mix them and conduct crushing treatment in a crusher. Add the crushed ore obtained after the crushing treatment to a ball mill, control the weight ratio of the crushed ore to the grinding beads to 1:2.5, mix and dry grind at a speed of 400 r / min for 90 min. After the dry grinding is completed, pass through a 500-mesh sieve to obtain a mixed mineral powder. Weigh 8 parts by weight of the mixed mineral powder, 0.1 part by weight of the organosilicon-modified dispersant obtained in Preparation Example 11 and 4 parts by weight of water, mix and stir for 2 h, and then age for 3 days to obtain the wear-resistant glaze slurry.

[0039] Preparation Example 18: A method for preparing a wear-resistant glaze slurry, specifically including the following process: Weigh 18 parts by weight of white fused alumina, 11 parts by weight of mullite, 4 parts by weight of glass fiber, 3 parts by weight of zirconium silicate and 12 parts by weight of wollastonite, mix them and conduct crushing treatment in a crusher. Add the crushed ore obtained after the crushing treatment to a ball mill, control the weight ratio of the crushed ore to the grinding beads to 1:2.5, mix and dry grind at a speed of 400 r / min for 90 min. After the dry grinding is completed, pass through a 500-mesh sieve to obtain a mixed mineral powder. Weigh 8 parts by weight of the mixed mineral powder, 0.1 part by weight of the organosilicon-modified dispersant obtained in Preparation Example 12 and 4 parts by weight of water, mix and stir for 2 h, and then age for 3 days to obtain the wear-resistant glaze slurry.

[0040] Preparation Example 19: A method for preparing a wear-resistant glaze slurry, specifically including the following process: Weigh 18 parts by weight of white fused alumina, 11 parts by weight of mullite, 4 parts by weight of glass fiber, 3 parts by weight of zirconium silicate and 12 parts by weight of wollastonite, mix them in a crusher for crushing treatment, add the crushed ore obtained after the crushing treatment to a ball mill, control the weight ratio of the crushed ore to the grinding beads to 1:2.5, and mix and dry grind at a speed of 400 r / min for 10 min to obtain a mixed mineral powder. Weigh 8 parts by weight of the mixed mineral powder, 0.1 part by weight of the organosilicon-modified dispersant obtained in Preparation Example 10 and 4 parts by weight of water, mix and stir for 2 h, and then age for 3 days to obtain a wear-resistant glaze slurry.

[0041] Preparation Example 20: A method for preparing a wear-resistant glaze slurry, specifically including the following process: Weigh 18 parts by weight of white fused alumina, 11 parts by weight of mullite, 4 parts by weight of glass fiber, 3 parts by weight of zirconium silicate and 12 parts by weight of wollastonite, mix them in a crusher for crushing treatment, add the crushed ore obtained after the crushing treatment to a ball mill, control the weight ratio of the crushed ore to the grinding beads to 1:2.5, mix and dry grind at a speed of 400 r / min for 90 min, and after the dry grinding is completed, pass through a 500-mesh sieve to obtain a mixed mineral powder. Weigh 8 parts by weight of the mixed mineral powder, 0.1 part by weight of sodium lignosulfonate and 4 parts by weight of water, mix and stir for 2 h, and then age for 3 days to obtain a wear-resistant glaze slurry.

[0042] Preparation Example 21: A method for preparing a wear-resistant glaze slurry, specifically including the following process: Weigh 18 parts by weight of white fused alumina, 11 parts by weight of mullite, 4 parts by weight of glass fiber, 3 parts by weight of zirconium silicate and 12 parts by weight of wollastonite, mix them in a crusher for crushing treatment, add the crushed ore obtained after the crushing treatment to a ball mill, control the weight ratio of the crushed ore to the grinding beads to 1:2.5, mix and dry grind for 90 min, and after the dry grinding is completed, pass through a 500-mesh sieve to obtain a mixed mineral powder. Weigh 8 parts by weight of the mixed mineral powder, 0.5 part by weight of the organosilicon-modified dispersant obtained in Preparation Example 10 and 4 parts by weight of water, mix and stir for 2 h, and then age for 3 days to obtain a wear-resistant glaze slurry.

[0043] Preparation Example 22: A method for preparing a wear-resistant glaze slurry, specifically including the following process: Weigh 18 parts by weight of white fused alumina, 11 parts by weight of mullite, 4 parts by weight of glass fiber, 3 parts by weight of zirconium silicate and 12 parts by weight of wollastonite, mix them in a crusher for crushing treatment, add the crushed ore obtained after the crushing treatment to a ball mill, control the weight ratio of the crushed ore to the grinding beads to 1:2.5, mix and dry-grind at a speed of 400 r / min for 90 min, and pass through a 500-mesh sieve after the dry-grinding to obtain a mixed mineral powder. Weigh 8 parts by weight of the mixed mineral powder and 4 parts by weight of water, mix and stir for 2 h, and then age for 3 days to obtain a wear-resistant glaze slurry. Example 1

[0044] A preparation method of a true wear-resistant ceramic tile specifically includes the following process: Use a glazing tool to glaze the wear-resistant glaze slurry obtained in Preparation Example 13 on the surface of the ceramic green body obtained in Preparation Example 1, control the glazing thickness to 0.5 mm, then place the glazed ceramic green body in a temperature environment of 130 °C for drying treatment for 30 min, and then put it into a muffle furnace, heat it up to 1180 °C at a heating rate of 20 °C / min and calcine for 1.5 h, and then naturally cool to obtain a ceramic tile. Example 2

[0045] A preparation method of a true wear-resistant ceramic tile specifically includes the following process: Use a glazing tool to glaze the wear-resistant glaze slurry obtained in Preparation Example 14 on the surface of the ceramic green body obtained in Preparation Example 2, control the glazing thickness to 0.6 mm, then place the glazed ceramic green body in a temperature environment of 140 °C for drying treatment for 30 min, and then put it into a muffle furnace, heat it up to 1200 °C at a heating rate of 20 °C / min and calcine for 1.5 h, and then naturally cool to obtain a ceramic tile. Example 3

[0046] A preparation method of a true wear-resistant ceramic tile specifically includes the following process: Use a glazing tool to glaze the wear-resistant glaze slurry obtained in Preparation Example 15 on the surface of the ceramic green body obtained in Preparation Example 3, control the glazing thickness to 0.6 mm, then place the glazed ceramic green body in a temperature environment of 150 °C for drying treatment for 30 min, and then put it into a muffle furnace, heat it up to 1220 °C at a heating rate of 20 °C / min and calcine for 2 h, and then naturally cool to obtain a ceramic tile. Example 4

[0047] A preparation method of a true wear-resistant ceramic tile specifically includes the following process: Use a glazing tool to apply the wear-resistant glaze slurry obtained in Preparation Example 16 onto the surface of the ceramic blank obtained in Preparation Example 4, control the glazing thickness to be 0.7 mm, then place the glazed ceramic blank in a temperature environment of 150 °C for drying treatment for 30 min, then put it into a muffle furnace, and heat it to 1240 °C at a heating rate of 20 °C / min for calcination for 2 h, and then naturally cool it to obtain a ceramic tile.

[0048] Comparative Example 1: A preparation method of a true wear-resistant ceramic tile, specifically including the following process: Use a glazing tool to apply the wear-resistant glaze slurry obtained in Preparation Example 16 onto the surface of the ceramic blank obtained in Preparation Example 5, control the glazing thickness to be 0.7 mm, then place the glazed ceramic blank in a temperature environment of 150 °C for drying treatment for 30 min, then put it into a muffle furnace, and heat it to 1240 °C at a heating rate of 20 °C / min for calcination for 2 h, and then naturally cool it to obtain a ceramic tile.

[0049] Comparative Example 2: A preparation method of a true wear-resistant ceramic tile, specifically including the following process: Use a glazing tool to apply the wear-resistant glaze slurry obtained in Preparation Example 16 onto the surface of the ceramic blank obtained in Preparation Example 6, control the glazing thickness to be 0.7 mm, then place the glazed ceramic blank in a temperature environment of 150 °C for drying treatment for 30 min, then put it into a muffle furnace, and heat it to 1240 °C at a heating rate of 20 °C / min for calcination for 2 h, and then naturally cool it to obtain a ceramic tile.

[0050] Comparative Example 3: A preparation method of a true wear-resistant ceramic tile, specifically including the following process: Use a glazing tool to apply the wear-resistant glaze slurry obtained in Preparation Example 17 onto the surface of the ceramic blank obtained in Preparation Example 4, control the glazing thickness to be 0.7 mm, then place the glazed ceramic blank in a temperature environment of 150 °C for drying treatment for 30 min, then put it into a muffle furnace, and heat it to 1240 °C at a heating rate of 20 °C / min for calcination for 2 h, and then naturally cool it to obtain a ceramic tile.

[0051] Comparative Example 4: A preparation method of a true wear-resistant ceramic tile, specifically including the following process: Use a glazing tool to apply the wear-resistant glaze slurry obtained in Preparation Example 18 onto the surface of the ceramic blank obtained in Preparation Example 4, control the glazing thickness to be 0.7 mm, then place the glazed ceramic blank in a temperature environment of 150 °C for drying treatment for 30 min, then put it into a muffle furnace, and heat it to 1240 °C at a heating rate of 20 °C / min for calcination for 2 h, and then naturally cool it to obtain a ceramic tile.

[0052] Comparative Example 5: A preparation method of a true wear-resistant ceramic tile, specifically including the following process: Use a glaze applicator to apply the wear-resistant glaze slurry obtained in Preparation Example 19 on the surface of the ceramic blank obtained in Preparation Example 4, control the glaze application thickness to be 0.7 mm, then place the glazed ceramic blank in a temperature environment of 150 °C for drying treatment for 30 min, and then put it into a muffle furnace, heat it up to 1240 °C at a heating rate of 20 °C / min and calcine for 2 h, and then naturally cool to obtain the ceramic tile.

[0053] Comparative Example 6: A preparation method of a true wear-resistant ceramic tile, specifically including the following process: Use a glaze applicator to apply the wear-resistant glaze slurry obtained in Preparation Example 20 on the surface of the ceramic blank obtained in Preparation Example 4, control the glaze application thickness to be 0.7 mm, then place the glazed ceramic blank in a temperature environment of 150 °C for drying treatment for 30 min, and then put it into a muffle furnace, heat it up to 1240 °C at a heating rate of 20 °C / min and calcine for 2 h, and then naturally cool to obtain the ceramic tile.

[0054] Comparative Example 7: A preparation method of a true wear-resistant ceramic tile, specifically including the following process: Use a glaze applicator to apply the wear-resistant glaze slurry obtained in Preparation Example 21 on the surface of the ceramic blank obtained in Preparation Example 4, control the glaze application thickness to be 0.7 mm, then place the glazed ceramic blank in a temperature environment of 150 °C for drying treatment for 30 min, and then put it into a muffle furnace, heat it up to 1240 °C at a heating rate of 20 °C / min and calcine for 2 h, and then naturally cool to obtain the ceramic tile.

[0055] Comparative Example 8: A preparation method of a true wear-resistant ceramic tile, specifically including the following process: Use a glaze applicator to apply the wear-resistant glaze slurry obtained in Preparation Example 22 on the surface of the ceramic blank obtained in Preparation Example 4, control the glaze application thickness to be 0.7 mm, then place the glazed ceramic blank in a temperature environment of 150 °C for drying treatment for 30 min, and then put it into a muffle furnace, heat it up to 1240 °C at a heating rate of 20 °C / min and calcine for 2 h, and then naturally cool to obtain the ceramic tile.

[0056] Use a micro-Vickers hardness tester to test the Vickers hardness of the ceramic tiles obtained in Examples 1 to 4 and Comparative Examples 1 to 8, and the results are shown in Table 1 below.

[0057]

[0058] In accordance with "GB / T 3810.7-2016 Test Methods for Ceramic Tiles - Part 7: Determination of Surface Abrasion Resistance of Glazed Tiles", the abrasion resistance of the ceramic tiles obtained in Examples 1 to 4 and Comparative Examples 1 to 8 was tested. The size was 100 mm × 100 mm. The results are shown in Table 2 below.

[0059]

[0060] In accordance with "GB / T 3810.7-2016 Test Methods for Ceramic Tiles - Part 3: Determination of Water Absorption, Apparent Porosity, Apparent Relative Density and Bulk Density", the water absorption of the ceramic tiles obtained in Examples 1 to 4 and Comparative Examples 1 to 8 was determined. The results are shown in Table 3 below.

[0061]

[0062] From the results of the above Tables 1 to 3, the following conclusions can be drawn: (1) It can be found from Examples 1 to 4 that the present invention applies the wear-resistant glaze slurry prepared from the organosilicon-modified dispersant and the mixed mineral powder on the surface of the ceramic body, achieving good hardness, abrasion resistance and low water absorption.

[0063] (2) It can be found from Comparative Example 1 that the abrasion resistance and hardness of the prepared ceramic tiles are poor, and the water absorption is high. This may be because although quartz has good hardness and wear resistance, adding too much in this system may cause a large difference in the thermal expansion coefficient between quartz itself and the materials in the wear-resistant glaze slurry, resulting in a large difference in the shrinkage degree, which may cause the wear-resistant glaze slurry to be subjected to excessive tensile stress, leading to cracking and breaking of the glaze layer. Moreover, the structure of quartz itself is relatively loose, which is easy to increase micropores, and then may lead to poor compactness, resulting in an increase in water absorption. The increase in water absorption is easy to cause the deformation of the ceramic tile, further affecting the hardness and abrasion resistance.

[0064] (3) It can be found from Comparative Example 2 that the abrasion resistance and hardness of the prepared ceramic tiles are poor, and the water absorption is high. This may be because although the binder can be removed by high-temperature calcination and decomposition, in the initial stage of mixing and preparation, excessive binder may hinder the combination between mineral particles, resulting in uneven mixing and bonding, and may instead make the internal structure of the green body loose and the pores increase, thus deteriorating the performance of the finally calcined ceramic tile.

[0065] (4) It can be found from Comparative Example 3 that the hardness and wear resistance of the prepared ceramic tiles are reduced, and the water absorption rate is increased. This may be because although vinyltriethoxysilane can crosslink with the hydroxyl groups on sodium lignosulfonate after hydrolysis to generate silanol groups in an acidic environment, due to the presence of unsaturated double bonds, the introduction of hydrophobic groups may affect the dispersion of the finer mixed mineral powder, possibly causing local aggregation, reducing the fluidity of the wear-resistant glaze slurry, and resulting in poor performance of the ceramic tiles.

[0066] (5) It can be found from Comparative Example 4 that the hardness and wear resistance of the prepared ceramic tiles are reduced, and the water absorption rate is increased. This may be because it is difficult for sulfonated melamine formaldehyde to crosslink and modify with the silane coupling agent through the condensation of silanol groups and hydroxyl groups, resulting in the fact that although sulfonated melamine formaldehyde can disperse the mixed mineral powder to prepare a wear-resistant glaze slurry, it is not resistant to high temperatures at the high-temperature stage and is prone to rapid decomposition, affecting the performance of the finally calcined ceramic tiles.

[0067] (6) It can be found from Comparative Example 5 that the hardness and wear resistance of the prepared ceramic tiles are reduced, and the water absorption rate is increased. This may be because the dry grinding time is short, resulting in too large particle size of the mixed mineral powder. If the particle size is too large, it is easy to generate more gaps during the mixed calcination. The increase in gaps easily causes the water absorption rate of the ceramic tiles to rise, and then affects the hardness and wear resistance.

[0068] (7) It can be found from Comparative Example 6 that the hardness and wear resistance of the prepared ceramic tiles are reduced, and the water absorption rate is increased. This may be because although unmodified sodium lignosulfonate can disperse the finer mixed mineral powder, due to its poor high-temperature resistance, it may easily cause sodium lignosulfonate to decompose too quickly during high-temperature calcination, thereby affecting the stable formation of the wear-resistant glaze slurry on the surface of the ceramic body, and finally making the performance of the ceramic tiles poor.

[0069] (8) It can be found from Comparative Example 7 that the hardness and wear resistance of the prepared ceramic tiles are reduced, and the water absorption rate is increased. This may be because although the organosilicon-modified dispersant helps to disperse the finer mixed mineral powder, excessive use may lead to an increase in the repulsive force between particles, hinder the fusion of particles during sintering, reduce the grain boundary bonding strength, and easily decompose to generate too much gas at high temperatures, forming pores and reducing the density of the ceramic tiles, thereby affecting the stable formation of the wear-resistant glaze slurry on the surface of the ceramic body, and finally making the performance of the ceramic tiles poor.

[0070] (9) It can be found from Comparative Example 8 that the hardness and wear resistance of the prepared ceramic tiles are reduced, and the water absorption rate is increased. This may be because the particle size of the mixed mineral powder is relatively fine, and simply adding water and mixing may be difficult to achieve effective dispersion and is prone to agglomeration, thereby making the performance of the ceramic tiles poor.

[0071] The above-described embodiments have elaborated in detail the technical solutions and beneficial effects of the present invention. It should be understood that the above are only specific embodiments of the present invention and are not intended to limit the present invention. Without departing from the spirit and scope of the present invention, the present invention will have various changes and improvements, and these changes and improvements all fall within the scope of the present invention claimed.

Claims

1. A truly wear-resistant ceramic tile, characterized in that: The ceramic brick is composed of a ceramic body and wear-resistant glaze slurry; The method for preparing the wear-resistant glaze slurry comprises the following steps: White corundum, mullite, glass fiber, zirconium silicate and wollastonite are mixed and crushed in a weight ratio of 15-18:8-11:1-4:2-3:6-12 to obtain crushed ore, and the crushed ore and grinding beads are mixed and dry-ground in a weight ratio of 1:2.5 and sieved to obtain mixed mineral powder; Weigh 5-8 parts by weight of mixed mineral powder, 0.08-0.1 parts by weight of organosilicon modified dispersant and 2-4 parts by weight of water in a weight ratio of 5-8:0.08-0.1:2-4, mix and stir, and age to obtain a wear-resistant glaze slurry; The preparation method of the organosilicon modified dispersant comprises the following steps: The silane coupling agent, the ethanol-water solution and the dispersant are mixed and stirred in a weight ratio of 1:95-100:10-12 to obtain a mixed solution, and the mixed solution is kept warm and reacted after adjusting the pH to 6.0-6.5 to obtain an organosilicon-modified dispersant; The silane coupling agent includes γ-aminopropyltrimethoxysilane or γ-aminopropyltriethoxysilane.

2. A true wear-resistant ceramic tile according to claim 1, characterized in that: The method for preparing the ceramic body comprises the following steps: Quartz, kaolin, glass powder, ceramic waste and plagioclase are mixed and crushed in a weight ratio of 1-2:19-25:11-14:17-21:3-6 to obtain a crushed material, and the crushed material, water and grinding beads are mixed and wet-milled in a weight ratio of 1:1:2 to obtain a green body slurry; The green body slurry and the binder are mixed in a weight ratio of 10:0.2-0.3, and then atomized and granulated to obtain green body powder. The green body powder is pressed and formed, and then dried to obtain a ceramic green body.

3. A true wear-resistant ceramic tile according to claim 1, characterized in that: The ethanol-water solution is composed of anhydrous ethanol and deionized water mixed in a weight ratio of 1:7-9.

4. A true wear-resistant ceramic tile according to claim 1, characterized in that: The dispersant includes sodium lignin sulfonate.

5. A true wear-resistant ceramic tile according to claim 1, characterized in that: The conditions of the heat preservation reaction include a reaction temperature of 30° C. to 40° C. and a reaction time of 4 h to 6 h.

6. A method for preparing a true wear-resistant ceramic tile as claimed in any one of claims 1 to 5, characterized in that: The preparation method comprises the following steps: The wear-resistant glaze slurry is glazed on the surface of the ceramic body by a glaze scraper, and the glazing thickness is controlled to be 0.5mm~0.7mm. It is then dried at 130℃~150℃ for 30min and then calcined at 1180℃~1240℃ for 1.5h~2h to obtain the ceramic tile.

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