A super-flat diamond glaze ceramic tile and its preparation method

Abstract

This invention discloses an ultra-flat diamond-glazed ceramic tile, comprising, from bottom to top, a body layer, a base glaze layer, a pattern layer, and a diamond glaze surface layer. The body layer, by weight, comprises 22-26 parts kaolin, 9-12 parts bauxite, 25-30 parts quartz sand, 4-6 parts bentonite, 16-20 parts potassium feldspar, 3-6 parts talc, 3-5 parts wollastonite, 2-3 parts nano-magnesium oxide, and 1-2 parts boron nitride. The aluminum content in the body layer is 18-22%. The diamond glaze surface layer is formed by spraying a top glaze. This invention, through optimization of the body formula, glaze formula, high-temperature slow-firing process, polishing process, and the construction of a hydrophobic layer, significantly outperforms traditional products in key indicators such as flatness, strength, wear resistance, hardness, antibacterial properties, and stain resistance. Furthermore, the glaze is more transparent and lustrous, the pattern effect is more realistic, and the mirror effect is more outstanding, making it suitable for high-requirement architectural decoration scenarios.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ceramic tiles, in particular to an ultra-flat diamond glaze ceramic tile and a preparation method thereof. BACKGROUND

[0002] As a basic building decoration material, ceramic tiles are widely used in residential, commercial and public buildings due to their durability, decorative diversity and cost controllability. From indoor floor tiles, wall tiles to outdoor plaza tiles, ceramic tiles not only bear the functional ground covering role, but also become an important carrier of spatial aesthetic expression. With the improvement of people's living standards, the demand for decoration is also getting higher and higher. The limitations of traditional ceramic tiles gradually appear. In terms of flatness, the traditional ceramic tiles have obvious warping phenomenon, which affects the overall appearance and laying effect of the tiles. In terms of strength, the traditional ceramic tiles have relatively low bending strength and breaking strength, which are easy to crack. In terms of wear resistance, the glaze hardness and wear resistance grade of the traditional ceramic tiles are limited, which are easy to scratch and wear, reducing the decorative effect and service life. In addition, the traditional ceramic tiles have poor stain resistance, and the surface is easy to adsorb stains and dust, increasing the difficulty and cost of cleaning and maintenance. Therefore, there is an urgent need for an ultra-flat diamond glaze ceramic tile with high strength, high wear resistance, excellent antibacterial property and stain resistance. SUMMARY

[0003] The present application relates to the technical field of ceramic tiles, in particular to an ultra-flat diamond glaze ceramic tile and a preparation method thereof.

[0004] To achieve the above-mentioned purpose, the present application provides the following technical scheme:

[0005] An ultra-flat diamond glaze ceramic tile, which comprises a body layer, a bottom glaze layer, a pattern layer and a diamond glaze surface layer from bottom to top. The body layer comprises kaolin 22-26 parts, bauxite 9-12 parts, quartz sand 25-30 parts, bentonite 4-6 parts, potassium feldspar 16-20 parts, talc powder 3-6 parts, wollastonite 3-5 parts, nano magnesium oxide 2-3 parts, and boron nitride 1-2 parts by weight. The aluminum content in the body layer is 18-22%. The diamond glaze surface layer is formed by spraying face glaze. The face glaze comprises alpha-alumina 18-22 parts, quartz powder 25-30 parts, lithium feldspar 20-25 parts, frit 20-24 parts, kaolin 5-8 parts, nano diamond powder 1.5-3 parts, nano titanium dioxide 2-4 parts, nano zinc oxide 1-2.5 parts, nano silicon dioxide 1-2 parts, nano indium tin oxide 0.5-1 parts, dispersant 0.5-1 parts, nano silver 0.1-0.3 parts, and silicon carbide 1-3 parts by weight.

[0006] Further, the dispersant is polyacrylic acid sodium or zirconium oxide.

[0007] Further, the body layer thickness is 10.5-11.5mm, and the diamond glaze layer thickness is 1-1.2mm.

[0008] The preparation method of the super-flat diamond glaze ceramic tile comprises the following steps:

[0009] S1: obtaining a body layer by batching, ball milling, sieving, spray granulation, aging, pressing and drying;

[0010] S2: preparing a base glaze slurry and spraying the base glaze on the body layer to form a base glaze layer;

[0011] S3: spraying a decorative pattern on the base glaze layer by an inkjet printer to form a pattern layer;

[0012] S4: pre-ultrasonic dispersion of nanoparticles for 20-30 minutes at 20-40 kHz;

[0013] S5: preparing a surface glaze slurry and spraying the surface glaze on the pattern layer, with a glazing amount of 1000-1200g / m 2 , a glaze layer thickness of 1-1.2mm, and a diamond glaze layer formed after drying;

[0014] S6: placing the ceramic tile sprayed with the surface glaze into a kiln for firing, first heating at a rate of 10-15℃ / min to 750-850℃, keeping the temperature for 30-40min, and then heating at a rate of 8-10℃ / min to 1250-1350℃, keeping the temperature for 45-60min;

[0015] S7: polishing the fired ceramic tile in sequence by rough polishing, fine polishing and mirror finishing, and removing 0.05-0.1mm of the glaze layer;

[0016] S8: spraying a hydrophobic agent on the polished ceramic tile, and curing at 150℃ for 10min to finally obtain the super-flat diamond glaze ceramic tile.

[0017] Further, in step S7, the rough polishing adopts a diamond grinding head with a mesh size of 400-800, at a rotating speed of 800-1000rpm, the fine polishing adopts a resin grinding disc with a mesh size of 1500-3000, at a rotating speed of 1200-1500rpm, the polishing liquid adopts a nano-SiO2 suspension, and the mirror finishing adopts a nano-level cerium oxide polishing paste, at a pressure of 0.1-0.2MPa.

[0018] Further, in step S8, the hydrophobic agent comprises, by weight fraction, anhydrous ethanol 45-50 parts, fluorosilane coupling agent 38-42 parts, nano-silicon dioxide 4-6 parts, epoxy-modified fluorosilicon resin 2-3 parts, deionized water 8-10 parts, and silane coupling agent 0.2-0.5 parts.

[0019] Compared with the prior art, the present application has the following beneficial effects:

[0020] The present application is significantly superior to traditional products in key indicators such as flatness, strength, wear resistance, hardness, antibacterial property, and stain resistance, and the glaze is more transparent, more moist, and the color effect is more realistic, and the mirror effect is more outstanding, and is suitable for high requirement building decoration scenes.

[0021] 1. The aluminum content in the body layer is optimized to 18-22%, and nano magnesium oxide and boron nitride are introduced to promote the formation of a dense and interwoven acicular mullite network structure, significantly improving the bending strength and toughness of the body, achieving the best balance of body strength and toughness, and effectively preventing cracks.

[0022] 2. The nano diamond glaze formula is used to form a molecular structure similar to C60 diamond, significantly improving the hardness and wear resistance of the glaze, and combining high temperature slow burning, increased glaze application amount, and multi-stage polishing process to enhance the glaze's wear resistance, achieving overall improvement in glaze flatness and texture, and achieving super-flat mirror effect on the brick surface, solving the water ripple problem of ordinary ceramic tiles.

[0023] 3. Through the synergistic effect of fluorosilane hydrophobic coating and nano silver antibacterial agent, an ultra-hydrophobic surface with a contact angle > 150° and a 99.9% antibacterial rate are achieved, significantly reducing the cleaning frequency. DETAILED DESCRIPTION

[0024] In order to make the technical problems, technical solutions and beneficial effects solved by the present application more clear and explicit, the present application will be further described in detail below in conjunction with examples. It should be understood that the specific examples described herein are only used to explain the present application, and are not intended to limit the present application. EMBODIMENT

[0025] An ultra-flat diamond glaze tile, from bottom to top, includes a body layer, a bottom glaze layer, a pattern layer, and a diamond glaze surface layer, the body layer includes, in parts by weight, kaolin 22-26 parts, bauxite 9-12 parts, quartz sand 25-30 parts, bentonite 4-6 parts, potassium feldspar 16-20 parts, talc powder 3-6 parts, wollastonite 3-5 parts, nano magnesium oxide 2-3 parts, and boron nitride 1-2 parts, the aluminum content in the body layer is 18-22%, the diamond glaze surface layer is formed by spraying face glaze, the face glaze includes, in parts by weight, alpha-alumina 18-22 parts, quartz powder 25-30 parts, lithium feldspar 20-25 parts, frit 20-24 parts, kaolin 5-8 parts, nano diamond powder 1.5-3 parts, nano titanium dioxide 2-4 parts, nano zinc oxide 1-2.5 parts, nano silicon dioxide 1-2 parts, nano indium tin oxide 0.5-1 parts, dispersing agent 0.5-1 parts, nano silver 0.1-0.3 parts, and silicon carbide 1-3 parts.

[0026] When the aluminum content in the ceramic body is 18-22%, a large number of long mullite fibers with high aspect ratio are formed in the ceramic body, forming a dense and interwoven needle-like mullite network structure. This network structure can effectively disperse stress, significantly improve the toughness and bending strength of the body, and effectively prevent the generation of cracks. Studies have shown that when the aluminum content is less than 18%, the amount of mullite generated is insufficient, and the strength of the body decreases. When the aluminum content exceeds 22%, the amount of liquid phase is too large, and the grain coarsens, which actually reduces the toughness.

[0027] In this embodiment, the body layer includes kaolin 24 parts, bauxite 10 parts, quartz sand 28 parts, bentonite 4 parts, potassium feldspar 18 parts, talc powder 5 parts, wollastonite 4 parts, nano magnesium oxide 3 parts, and boron nitride 2 parts. The aluminum content in the body layer is 19.5%, which significantly improves the bending toughness of the body and achieves the best balance between body strength and toughness. The face glaze includes α-alumina 20 parts, quartz powder 26 parts, lithium feldspar 22 parts, frit 20 parts, kaolin 6 parts, nano diamond powder 2 parts, nano titanium dioxide 2 parts, nano zinc oxide 1 part, nano silicon dioxide 1 part, nano indium tin oxide 0.5 parts, dispersant 0.5 parts, nano silver 0.2 parts, and silicon carbide 2 parts.

[0028] Kaolin provides Al2O3 and SiO2 for the body, forms the body skeleton, gives plasticity, and ensures the stability of the body forming. During the sintering process, kaolin can react with other components to form minerals such as mullite, improving the strength and toughness of the body; bauxite is one of the main raw materials of the ceramic body, providing Al2O3, reacting with SiO2 to form mullite and form a three-dimensional network structure, improving the strength and toughness of the body and inhibiting the cracking of the body; the main component of quartz sand is SiO2, which has high hardness and participates in the formation of mullite, which can improve the hardness, wear resistance and thermal stability of the body; bentonite as a binder has good plasticity, which can improve the plasticity, toughness and absorption of free water of the body to prevent drying cracking, reduce forming defects and improve the forming performance of the body; potassium feldspar as a fluxing agent promotes the formation of glass phase and improves the body density; talc powder introduces MgO, which helps to reduce the thermal expansion coefficient and improve the sintering performance of the body. At the same time, it generates cordierite (2MgO·2Al2O3·5SiO2), improves the thermal shock resistance of the body, and also improves the whiteness of the body, making the surface of the ceramic tile more beautiful; wollastonite provides CaO, promotes the generation of liquid phase, optimizes the sintering structure, reduces shrinkage deformation, and can form needle-like or fibrous crystals during the sintering process, improving the strength and toughness of the body; nano magnesium oxide as a mineralizer accelerates the crystallization of mullite, refines the grain, and enhances the mechanical properties of the body; boron nitride improves the grain boundary bonding, inhibits crack propagation, and improves the toughness and thermal shock resistance.

[0029] The core support framework of the alpha-alumina forms a diamond glaze surface layer, improves the hardness and high wear resistance of the glaze surface, and the uniformly distributed nano-level particles can effectively resist daily scratches, enhance the anti-scratching performance, and prolong the service life of the ceramic tile; the quartz powder forms a SiO2 glass phase by high-temperature melting, forms a eutectic structure with the alpha-alumina, improves the thermal stability, increases the hardness and gloss of the glaze surface, and improves the transparency of the glaze layer; the potassium feldspar introduces lithium ions to optimize the surface tension of the glaze surface, enhances the compactness of the glaze layer, reduces the pinhole rate of the glaze surface, improves the flatness and gloss of the glaze surface; the frit contains B2O3, Na2O and other components, the pre-synthesized amorphous glass body stabilizes the chemical composition of the glaze, adjusts the fluidity and sintering range of the glaze, and provides good melting performance and uniformity of the glaze layer; the kaolin improves the plasticity and sintering performance of the glaze, and enhances the adhesion of the glaze layer in combination with alumina to prevent drying shrinkage cracking; the nano-diamond powder significantly improves the hardness and wear resistance of the glaze surface, and at the same time gives the glaze surface a diamond-like gloss; the nano-titanium dioxide enhances the light transmittance of the glaze surface, makes the glaze layer more transparent, enhances the visual effect of the glaze surface, improves the three-dimensional effect of the color, makes the color more lifelike and vivid, and at the same time produces a photocatalytic effect under light, realizing a self-cleaning function; the nano-zinc oxide constructs a ZnO quantum dot antibacterial layer, and cooperates with the nano-titanium dioxide to improve the photocatalytic efficiency, improve the antibacterial performance and anti-fouling ability of the glaze surface, and at the same time improve the gloss of the glaze layer; the nano-silicon dioxide forms a nano-level network structure, enhances the bending strength of the glaze surface, at the same time improves the flatness of the glaze surface, fills the micro-pores, and improves the compactness and anti-fouling property of the glaze surface; the nano-indium tin oxide provides good electrical conductivity and optical transparency, enhances the anti-static performance of the glaze surface, and prevents dust adsorption; the dispersant prevents the agglomeration of nano-particles, ensures uniform dispersion of the nano-components, at the same time improves the rheological property of the glaze, and ensures uniform distribution of the glaze layer; the dispersant can be sodium polyacrylate or zirconium oxide; the nano-silver gives the glaze surface antibacterial and mildew-proof functions, and at the same time improves the self-cleaning performance of the glaze surface; the silicon carbide enhances the impact resistance of the glaze layer, at the same time cooperates with the nano-diamond powder to form a diamond-like structure, and effectively improves the wear resistance.

[0030] In the embodiment, the thickness of the body layer is 11 mm, which is thicker than that of the traditional diamond glaze ceramic tile, so that the R angle can be better controlled, and the thickness of the diamond glaze surface layer is 1-1.2 mm, which is 1.07 mm before polishing and 1.02 mm after polishing.

[0031] The preparation method of the super-flat diamond glaze ceramic tile comprises the following steps:

[0032] S1: obtaining the body layer by batching, ball milling, sieving, spray granulation, aging, pressing and drying;

[0033] S2: preparing a bottom glaze slurry and spraying the bottom glaze on the body layer to form a bottom glaze layer;

[0034] S3: printing a decorative pattern on the base glaze layer by an inkjet printer to form a pattern layer;

[0035] S4: pre-ultrasonic dispersion of the nanoparticles for 20-30 minutes at 20-40 kHz to break the agglomeration of the nanoparticles by ultrasonic waves and ensure uniform distribution of the nanoparticles in the glaze slurry, thereby improving the glaze performance;

[0036] S5: preparing a face glaze and spraying the face glaze on the pattern layer, the glazing amount being 1000 g / m2 and the glaze layer thickness being 1.07 mm, the glazing amount being increased by about 20% compared with the traditional diamond glaze tile, so that the glaze is more transparent and smooth, and the color effect is more realistic, and a diamond glaze surface layer is formed after drying, thereby giving the tile super-hard wear resistance, high gloss and stain resistance;

[0037] S6: placing the tile sprayed with the face glaze into a kiln for firing, first heating at a rate of 10-15 ℃ / min to 800 ℃, keeping the temperature for 30-40 min, and then heating at a rate of 8-10 ℃ / min to 1250 ℃, keeping the temperature for 60 min, so as to ensure that the glaze is fully melted and tightly combined with the body;

[0038] S7: polishing the fired tile by rough polishing, fine polishing and mirror surface treatment in sequence, and removing 0.05-0.1 mm of the glaze layer, so that the mirror surface effect of the tile surface is more outstanding, and the generation of water ripples is greatly reduced;

[0039] S8: spraying a hydrophobic agent on the polished tile, and curing at 150 ℃ for 10 min to finally obtain a super-flat diamond glaze tile, and the hydrophobic agent is used to build a lotus effect hydrophobic layer to improve the stain resistance.

[0040] In step S7, the diamond grinding head with a mesh size of 400-800 is used for rough polishing at a speed of 800-1000 rpm to remove the glaze protrusions and firing defects; the resin grinding disc with a mesh size of 1500-3000 is used for fine polishing at a speed of 1200-1500 rpm, and the polishing liquid is a nano-SiO2 suspension to refine the surface to a matte or semi-gloss effect; the nano-level cerium oxide polishing paste is used for mirror surface treatment at a pressure of 0.1-0.2 MPa to achieve mirror gloss.

[0041] In step S8, the hydrophobic agent includes, by weight fraction, anhydrous ethanol 45-50 parts, fluorosilane coupling agent 38-42 parts, nano-SiO2 4-6 parts, epoxy modified fluorosilicon resin 2-3 parts, deionized water 8-10 parts, and silane coupling agent 0.2-0.5 parts, and a low surface energy coating is formed by the fluorosilane coupling agent and the nano-SiO2 to give the tile hydrophobic and stain-resistant properties.

[0042] Anhydrous ethanol as solvent; fluorosilane coupling agent as main hydrophobic agent, combined with glaze through Si-O bond to form low surface energy film layer; nano-silicon dioxide to construct micro-nano rough structure, to improve contact angle to super-hydrophobic (> 150°); deionized water to promote fluorosilane hydrolysis; silane coupling agent to assist dispersion of nano-silicon dioxide, to improve interfacial bonding strength. Example

[0043] The difference between Example One and Example Two is that the body layer includes kaolin 26 parts, bauxite 9 parts, quartz sand 30 parts, bentonite 5 parts, potassium feldspar 20 parts, talc powder 3 parts, wollastonite 4 parts, nano-magnesium oxide 2 parts, and boron nitride 2 parts by weight fraction. The glaze application amount is 1050 g / m2, the glaze layer thickness is 1.13 mm, the firing temperature is 1300℃, and the polished glaze layer thickness is 1.08 mm.

[0044] The body layer of the traditional ceramic tile includes kaolin 30 parts, quartz sand 25 parts, bentonite 8 parts, potassium feldspar 25 parts, talc powder 5 parts, and wollastonite 3 parts by weight fraction. The aluminum content in the body layer is 17.1%. The glaze includes aluminum oxide 20 parts, quartz powder 26 parts, lithium feldspar 22 parts, frit 20 parts, kaolin 10 parts, zinc oxide 4 parts, and wollastonite 5 parts by weight fraction. The preparation method includes the following steps:

[0045] S1: obtaining the body layer by batching, ball milling, sieving, spray granulation, aging, pressing, and drying;

[0046] S2: preparing the bottom glaze paste and spraying the bottom glaze on the body layer to form the bottom glaze layer;

[0047] S3: printing the decorative pattern on the bottom glaze layer by an inkjet printer to form the pattern layer;

[0048] S4: preparing the top glaze paste and spraying the top glaze on the pattern layer with an application amount of 850 g / m2;

[0049] S5: placing the ceramic tile sprayed with the top glaze into a kiln and firing at 1150℃ for 60 min;

[0050] S6: polishing the fired ceramic tile, and the polished glaze layer thickness is 0.86 mm to obtain the ceramic tile.

[0051] The test results of the ceramic tiles prepared in Example One, Example Two, and the Comparative Example are shown in Table One.

[0052] Table One: Comparison of Test Results

[0053]

[0054] Through the above table analysis, it can be seen that the first and second examples are significantly superior to the traditional products in the key indicators of flatness, strength, wear resistance, hardness, antibacterial property, and stain resistance, etc. by optimizing the body formula (aluminum content, etc.), glaze formula (nano materials, antibacterial components, etc.), high-temperature slow firing process, polishing process, and constructing a hydrophobic layer, and the glaze is more transparent, more moist, the color effect is more realistic, the mirror effect is more outstanding, and is suitable for high requirement building decoration scenes.

[0055] While embodiments of the application have been shown and described, it is to be understood that the embodiments described are merely exemplary of the principles and application of the present application. Numerous modifications and adaptions can be made without departing from the spirit and scope of the present application, which is defined by the following claims and their equivalents.

Claims

1. A super-flat vitreous enamel tile, characterized by, From bottom to top, the body layer, the bottom glaze layer, the pattern layer and the diamond glaze surface layer are sequentially included, the body layer includes kaolin 22-26 parts, bauxite 9-12 parts, quartz sand 25-30 parts, bentonite 4-6 parts, potassium feldspar 16-20 parts, talc powder 3-6 parts, wollastonite 3-5 parts, nano magnesium oxide 2-3 parts, boron nitride 1-2 parts by weight fraction, the aluminum content in the body layer is 18-22%, the diamond glaze surface layer is formed by face glaze spraying, the face glaze includes alpha-aluminum oxide 18-22 parts, quartz powder 25-30 parts, lithium feldspar 20-25 parts, frit 20-24 parts, kaolin 5-8 parts, nano diamond powder 1.5-3 parts, nano titanium dioxide 2-4 parts, nano zinc oxide 1-2.5 parts, nano silicon dioxide 1-2 parts, nano indium tin oxide 0.5-1 parts, dispersant 0.5-1 parts, nano silver 0.1-0.3 parts, silicon carbide 1-3 parts by weight fraction.

2. The super-smooth diamond-finished ceramic tile according to claim 1, characterized in that, The dispersant uses sodium polyacrylate or zirconium oxide.

3. The super-smooth feldspathic tile according to claim 1, characterized in that, The thickness of the body layer is 10.5-11.5mm, and the thickness of the diamond glaze surface layer is 1-1.2mm.

4. A method of producing the super-flat corundum enamel tile according to any one of claims 1 to 3, characterized in that, The method comprises the following steps: S1: obtaining the body layer by batching, ball milling, sieving, spray granulation, aging, pressing and drying; S2: preparing the bottom glaze slurry and spraying the bottom glaze on the body layer to form the bottom glaze layer; S3: spraying the decorative pattern on the bottom glaze layer by an inkjet printer to form the pattern layer; S4: pre-ultrasonic dispersion of the nano particles for 20-30 minutes at 20-40kHz; S5: prepare a face glaze and spray the face glaze on the pattern layer, the amount of glaze 1000-1200g / m 2 , the glaze layer thickness 1-1.2mm, and a dried diamond glaze layer is formed. S6: placing the ceramic tile sprayed with the face glaze into a kiln for firing, first heating at a rate of 10-15℃ / min to 750-850℃, keeping the temperature for 30-40min, then heating at a rate of 8-10℃ / min to 1250-1350℃, keeping the temperature for 45-60min; S7: polishing the fired ceramic tile in sequence by rough polishing, fine polishing and mirror finishing, and removing the glaze layer by 0.05-0.1mm; S8: spraying the hydrophobic agent on the polished ceramic tile, and curing at 150℃ for 10min to finally obtain the super-flat diamond glaze ceramic tile.

5. The method for preparing super-smooth diamond-finished porcelain tiles according to claim 4, characterized in that, In step S7, the rough polishing uses a diamond grinding head with a mesh size of 400-800, the rotating speed is 800-1000rpm, the fine polishing uses a resin grinding disc with a mesh size of 1500-3000, the rotating speed is 1200-1500rpm, the polishing liquid uses a nano SiO2 suspension, and the mirror finishing uses a nano cerium oxide polishing paste with a pressure of 0.1-0.2MPa.

6. The method of producing super-smooth diamond-like porcelain tiles according to claim 4, characterized in that, In step S8, the hydrophobic agent includes anhydrous ethanol 45-50 parts, fluorosilane coupling agent 38-42 parts, nano silicon dioxide 4-6 parts, epoxy modified fluorosilicon resin 2-3 parts, deionized water 8-10 parts, silane coupling agent 0.2-0.5 parts by weight fraction.

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