A pore simulation generating agent and a preparation method thereof, and a ceramic plate and a preparation method thereof

Abstract

The application provides a pore simulation generating agent and a preparation method thereof, a ceramic plate and a preparation method thereof. The pore simulation generating agent is used for being added into a bottom material layer of the ceramic plate. Raw material formula of the pore simulation generating agent comprises, in terms of weight parts, 0-15 parts of urea and / or liquid paraffin, 10-30 parts of production powder and 55-75 parts of special solid low-carbon fuel particles. The pore simulation generating agent prepared by using urea and / or liquid paraffin, production powder and special solid low-carbon fuel particles has a low carbon residue amount of urea and liquid paraffin, and most of the urea and liquid paraffin can be decomposed or combusted before 600 DEG C in a drying or sintering stage, so that the problem that the carbon residue amount of the existing pore generating agent is too high, the pore generating agent cannot be completely volatilized after high-temperature sintering, and a large number of glaze defects are easily caused can be solved.

Description

Technical Field

[0001] This invention relates to the field of ceramic production technology, and in particular to a pore-simulating agent and its preparation method, as well as a ceramic plate and its preparation method. Background Technology

[0002] The stability of tile installation is related to people's safety. Due to large temperature differences in climate or long-term exposure to wind, sun and rain, coupled with the difference in deformation rate between the tile and the adhesive material, the tile slabs are prone to detachment, causing the tile panel to fall off, which may lead to safety accidents. However, by changing the structure of the tile back pattern, the bonding strength between the tile and the wall can be increased.

[0003] Currently, most ceramic tile back patterns are formed by molding and pressing, with the depth of the pressed back patterns generally between 0.6-0.8mm. However, the patterns produced by molding and pressing are very limited. Other methods of preparing back patterns include applying adhesive and adding pore-forming agents. However, back patterns obtained by molding and applying adhesive can cause ceramic tiles to easily fall off during later installation and bonding. Existing pore-forming agents are selected from polystyrene, modified starch, polymethyl methacrylate, polyethylene, polycarbonate, polybutene, and polyisoprene. These pore-forming agents have too high a residual carbon content, which cannot be completely volatilized quickly after high-temperature firing, easily causing a large number of glaze defects.

[0004] Therefore, existing technologies have shortcomings and need to be improved and developed. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a pore simulation generating agent and its preparation method, as well as a ceramic plate and its preparation method, in response to the above-mentioned defects of the prior art. The aim is to solve the problem that the residual carbon content of the pore-forming agent in the prior art is too high, and it cannot be completely volatilized as soon as possible after high-temperature firing, which easily causes a large number of glaze defects.

[0006] The technical solution adopted by this invention to solve the technical problem is as follows:

[0007] A pore-simulating agent is used to be added to the substrate layer of a ceramic slab, wherein the raw material formulation of the pore-simulating agent, by weight, comprises:

[0008] 0-15 parts urea and / or liquid paraffin, 10-30 parts production powder, and 55-75 parts special solid low-carbon fuel pellets.

[0009] In one embodiment of this application, the raw material formulation of the specially formulated solid low-carbon fuel pellets, by weight, includes:

[0010] 90-95 parts industrial alcohol, 30-40 parts pearl cotton powder, 4.6-6.6 parts stearic acid, 1.0-1.2 parts sodium hydroxide, and 4-4.5 parts water.

[0011] In one embodiment of this application, the preparation steps of the specially formulated solid low-carbon fuel pellets include:

[0012] Stearic acid was added to industrial alcohol, and the mixture was heated and stirred in a water bath until homogeneous to obtain the first mixture.

[0013] Pearl cotton powder is added to the first mixture, heated and stirred in a water bath until uniform, to obtain the second mixture.

[0014] Sodium hydroxide was dissolved in water and shaken thoroughly to obtain the third mixture.

[0015] Industrial alcohol was added to the third mixture, and the mixture was heated and stirred in a water bath until it was homogeneous, thus obtaining the fourth mixture.

[0016] The fourth mixture is added to the second mixture, heated and stirred in a water bath, and then cooled and solidified naturally to obtain a solidified product.

[0017] The solidified material is cut into specially made solid low-carbon fuel particles.

[0018] In one embodiment of this application, the chemical composition of the production powder, by mass percentage, includes:

[0019] Loss on ignition 4–6%, SiO2 64–70%, Al2O3 20–22%, Fe2O3 0.1–0.3%, CaO 1–3%, MgO 1–3%, K2O 1–3%, Na2O 1–5%, Li2O 0–0.5% 。

[0020] In one embodiment of this application, the pore simulation agent exists in solid form at temperatures below 60°C, has a melting point or ignition point of 120-130°C, and a high-temperature residual carbon content of less than 0.55% at 600°C.

[0021] This application also provides a method for preparing the pore-simulating agent as described above, wherein the method includes:

[0022] Weigh out 0-15 parts of urea and / or liquid paraffin, 10-30 parts of production powder, and 55-75 parts of special solid low-carbon fuel pellets by weight, and mix them to form a powder.

[0023] The dough is pressed into thin cakes using a double-roll mill.

[0024] After the thin cake is crushed, it is sieved through a 30-50 mesh sieve to form solid powder particles, which are then used as pore-simulating agents.

[0025] This application also provides a method for preparing a ceramic plate, wherein the method for preparing the ceramic plate includes:

[0026] Obtain a pre-prepared base material, and mix the base material with the hole simulation generating agent as described above to obtain a texture powder;

[0027] According to the preset digital fabric process requirements, the base texture powder is added to the corresponding material tank of the through-body digital fabricer, and the digital fabric is first reverse-blown on the steel strip of the through-body digital fabricer to form a base material layer.

[0028] A pre-prepared fabric is obtained, and the fabric is laid on the base material layer to form a fabric layer. After drying, a ceramic body is obtained; the ceramic body is then processed and fired.

[0029] During the drying process, the pore-simulating agent is burned and volatilized or decomposed into gas to form pores in the substrate layer; during the firing process, the residual carbon after the pore-simulating agent is burned completely, and finally a ceramic plate with pore back texture structure is obtained.

[0030] In one embodiment of this application, a surface layer is laid on the base material layer, and a ceramic body is obtained after drying, comprising:

[0031] A fabric layer is laid on the base material layer, and the material is dried at a drying temperature of 150-330℃ for a drying time of 65-95 minutes to obtain a ceramic body.

[0032] In one embodiment of this application, the firing temperature of the ceramic body is 1150-1220℃, and the firing time is 45-85 minutes.

[0033] This application also provides a ceramic plate, wherein the ceramic plate is prepared by the ceramic plate preparation method described above.

[0034] This application provides a pore-simulating agent and its preparation method, as well as a ceramic plate and its preparation method. The pore-simulating agent is added to the base layer of the ceramic plate. The raw material formula of the pore-simulating agent, by weight, includes: 0-15 parts of urea and / or liquid paraffin, 10-30 parts of production powder, and 55-75 parts of specially made solid low-carbon fuel particles. This application provides a pore-simulating agent prepared using urea and / or liquid paraffin, production powder, and specially made solid low-carbon fuel particles. The urea and liquid paraffin have low residual carbon content and are easily decomposed or burned completely. Therefore, it can solve the problem of existing pore-forming agents having too high residual carbon content, failing to volatilize quickly after high-temperature firing, and easily causing numerous glaze defects. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the structure of a ceramic plate according to the present invention.

[0036] Figure 2 This is a diagram illustrating the effect of the holes in the first specific embodiment of the present invention.

[0037] Figure 3 This is a diagram illustrating the effect of the holes in the second specific embodiment of the present invention.

[0038] Figure 4 This is a diagram illustrating the effect of the holes in the third specific embodiment of the present invention. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of this invention clearer and more explicit, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0040] In recent years, the domestic production and demand for ceramic slabs / large slabs have shown a steady growth trend and continued expansion in applications. The development of ceramic machinery equipment is also gradually trending towards larger and more flexible slabs. Currently, there are three main forming methods for slabs / large slabs: dry-pressing traditional forming, moldless belt forming, and roll forming. Specifically, the dry-pressing traditional forming method involves loading powder into a metal mold and compressing it under force. Gas in the voids within the blank is partially expelled, causing particles to shift, gradually move closer together, and interlock tightly, ultimately forming a blank with a cross-section identical to the mold's cross-section, and the shape of the upper and lower surfaces determined by the mold's upper and lower pressure heads. The moldless belt forming method involves evenly distributing powder onto the surface of a conveyor belt according to a predetermined size. After distribution, the powder is transported by the conveyor belt to a pressure device for pressing and forming. The roll forming method uses a feeding system where ceramic powder is distributed on a traction steel belt driven by two very rigid motors. The rotating steel belt feeds the uniformly thick ceramic powder between a pair of opposing pressure rollers for roll forming. It can produce brick blanks with a width of 1600mm and unlimited length. Roll forming features low power consumption, low noise, low pollution, high efficiency, and highly flexible production. It also has unparalleled advantages over traditional presses in manufacturing, transportation, and installation.

[0041] For extra-large and thicker slabs, moldless belt forming and roll forming are common and offer a significant quality advantage. However, since tile adhesive is widely used for installation abroad, most slabs / large panels produced by this process are flat and lack backing patterns. Frequent replacement of imported belts or steel belts with backing patterns leads to higher costs. Compared to the moldless belt forming technology, traditional roll forming with steel belts featuring three-dimensional engraved backing patterns is more expensive.

[0042] Currently, the main technical approaches for back texture preparation are as follows: applying adhesive to steel strips, carving the green blank, and forming the back texture after firing with a pore-forming agent.

[0043] However, existing pore-forming agents selected from at least one of polystyrene, modified starch, polymethyl methacrylate, polyethylene, polycarbonate, polybutene, and polyisoprene have the following drawbacks:

[0044] First, the residual carbon content of this type of pore-forming agent is too high, and it cannot be completely volatilized quickly after high-temperature firing, which easily causes a large number of glaze defects, limiting its application to personalized travertine products.

[0045] Secondly, the pore-forming agent itself has no binding properties and a very low density in the above-mentioned pore-forming agent process. It is also not easy to combine with powder, which makes it easy to drift, delaminate, and separate in the digital fabric feeder, resulting in failure to achieve the expected design pattern position effect and positioning failure.

[0046] This application provides a hole simulation generator to address the common problems of material placement failure and glaze defects in conventional high-temperature firing hole-forming techniques for creating back textures. Furthermore, it aims to improve the positioning of hole-forming agents in digital fabricators, which often experience drift, layering, and separation when using drying or kiln preheating low-temperature zone hole-forming techniques. This eliminates the need for additional molds to form back textures, enhances production applicability, significantly improves product quality, and saves production costs.

[0047] like Figure 1 As shown, this application provides a pore-simulating agent for adding to the base layer of a ceramic slab. The raw material formulation of the pore-simulating agent, by weight, includes:

[0048] 0-15 parts urea and / or liquid paraffin, 10-30 parts production powder, and 55-75 parts special solid low-carbon fuel pellets.

[0049] Specifically, the ceramic slab base layer of this application includes: a base material and a pore-simulating agent. In one embodiment, the mass ratio of the base material to the pore-simulating agent is (95-98):(2-5). Different amounts of pore-simulating agent can form a back texture structure with different pore structures. As the amount of pore-simulating agent increases, the formed pore structure changes from isolated pores and interconnected pores to a groove structure. The amount of pore-simulating agent added can be adjusted according to the actual effect requirements of subsequent installation.

[0050] This application utilizes a hole-simulating agent, which, after drying and firing, forms irregular isolated holes, interconnected holes, or groove structures. These structures are then used as the back pattern for ceramic slabs or large ceramic tiles via digital fabrication, replacing the traditional molding back pattern process. Specifically, compared to mold-formed back patterns, this invention combines fabrication with special hole-simulating production technology, resulting in more flexible and diverse back pattern designs. Furthermore, the irregular cross-sections or projections of the hole structures formed by the hole-simulating agent, compared to the flat surfaces of mold-formed tiles, increase the contact area with traditional concrete mortar or tile adhesives during subsequent bonding, thereby improving the bonding strength of the ceramic slab.

[0051] In this embodiment of the application, the raw material formula of the specially made solid low-carbon fuel pellets, by weight, includes:

[0052] 90-95 parts industrial alcohol, 30-40 parts pearl cotton powder, 4.6-6.6 parts stearic acid, 1.0-1.2 parts sodium hydroxide, and 4-4.5 parts water.

[0053] Specifically, EPE (Expanded Polyethylene) is made from low-density polyethylene through physical foaming, with a melting point range of 110℃-125℃. EPE powder is the physical form of EPE; it remains solid particles below 60℃. Stearic acid is a common fatty acid with a melting point range of 56℃-69.6℃; therefore, it gradually solidifies below 60℃. Sodium hydroxide (NaOH) is a strong alkali with a melting point of 318℃. It also remains solid below 60℃. Therefore, the raw materials for specially formulated solid low-carbon fuel pellets are mostly solid below 60℃, with the particle size controlled to less than 60 mesh. Above 150℃, most of the carbon can volatilize or burn, and the residual carbon can be completely burned with extremely low residual carbon content at around 600℃ during later firing, thus preventing other defects in the glaze. Gases will be generated and pores will be left during the drying or firing stage of ceramic slabs or large plates, and the residual carbon content at high temperatures of around 600°C will be less than 0.55%.

[0054] Mixtures of one or more, such as urea or biomass fuel, may have low residual carbon content and be easily decomposed or burned without causing other defects in the glaze. However, solid granular materials themselves lack binding properties, have low density, and are not easy to combine with powder. They are very easy to disperse into powder during processing and are not easy to form solid powder clumps. This can also lead to easy drifting, layering, and separation in the digital fabricator. Because the position cannot be fixed, the formed holes cannot achieve the expected design pattern effect.

[0055] In the specially formulated solid low-carbon fuel particles of this application, stearic acid and sodium hydroxide undergo a saponification reaction under water bath heating conditions to produce sodium stearate and water. Sodium stearate is a long-chain fatty acid salt with surfactant properties. In the system, sodium stearate acts as a binder; its long-chain structure can form physical or chemical bonds with raw materials such as industrial alcohol and pearl cotton powder. Specifically, the long-chain molecules of sodium stearate intertwine with the microporous structure of pearl cotton powder through van der Waals forces, forming a mechanical bond. The polar end (sodium carboxylate group) of sodium stearate forms hydrogen bonds with the hydroxyl groups in industrial alcohol, while the non-polar end (long-chain alkyl group) interacts with the hydrophobic portion of pearl cotton powder, enhancing the cohesive force of the system. Industrial alcohol acts as a solvent, promoting the uniform dispersion of stearic acid and sodium hydroxide and accelerating the saponification reaction. The sodium stearate produced in the reaction has low solubility in alcohol; upon cooling, it forms a gel system, binding alcohol molecules between interconnected macromolecules, making the system non-flowing, thus solidifying and shaping. Pearl cotton powder is a polyethylene foam material with a porous structure that can adsorb sodium stearate and alcohol to form a stable network structure.

[0056] Therefore, the specially formulated solid low-carbon fuel particles of this application have binding properties and can easily combine with production powders, promoting the formation of solid powder particles by the pore simulation generator. As a result, they are less likely to drift, separate, or separate in the digital fabricator, thus improving the success rate of pore formation.

[0057] In one embodiment of this application, the preparation steps of the specially formulated solid low-carbon fuel pellets include:

[0058] Step S10: Add stearic acid to industrial alcohol, heat and stir in a water bath until homogeneous to obtain the first mixture;

[0059] Step S20: Add pearl cotton powder to the first mixture, heat and stir in a water bath until uniform to obtain the second mixture;

[0060] Step S30: Dissolve sodium hydroxide in water, shake well to obtain the third mixture;

[0061] Step S40: Add industrial alcohol to the third mixture, heat and stir in a water bath until uniform to obtain the fourth mixture;

[0062] Step S50: Add the fourth mixture to the second mixture, heat and stir in a water bath, and after stirring evenly, allow it to cool and solidify naturally to obtain a solidified product;

[0063] Step S60: Cut the solidified material into specially made solid low-carbon fuel particles.

[0064] Specifically, in step S10, stearic acid is added to industrial alcohol, heated and stirred in a water bath at 60°C for 3-4 minutes until homogeneous, resulting in a first mixture. In step S20, 60-mesh pearl cotton powder is added to the first mixture, heated and stirred in a water bath at 60°C for 5-6 minutes until homogeneous, resulting in a second mixture. In step S30, 90-95 parts of sodium hydroxide are dissolved in 4-4.5 parts of water, shaken for 2-3 minutes until homogeneous, resulting in a third mixture. In step S40, industrial alcohol is added to the third mixture, heated and stirred in a water bath at 60°C for 2-3 minutes until homogeneous, resulting in a fourth mixture. In step S50, the fourth mixture is added to the second mixture, heated and stirred in a water bath at 60°C for 4-5 minutes until homogeneous, then allowed to cool and solidify naturally, and cut into specially made solid low-carbon fuel pellets using a blade.

[0065] This application embodiment ensures that the raw materials react fully and disperse evenly by using step-by-step mixing. First, stearic acid is mixed with industrial alcohol, then pearl cotton powder is added, and finally it is mixed with sodium hydroxide solution, avoiding localized uneven reactions that may be caused by direct mixing; water bath heating provides a mild and uniform heating environment, which is conducive to the saponification reaction and prevents local overheating that could lead to the decomposition of raw materials.

[0066] In this embodiment of the application, the chemical composition of the production powder, by mass percentage, includes:

[0067] Loss on ignition 4–6%, SiO2 64–70%, Al2O3 20–22%, Fe2O3 0.1–0.3%, CaO 1–3%, MgO 1–3%, K2O 1–3%, Na2O 1–5%, Li2O 0–0.5% 。

[0068] Specifically, the moisture content of the production powder is 8-10%.

[0069] In one embodiment of this application, the pore-simulating agent exists in solid form at temperatures below 60°C, with a melting point or ignition point of 120–130°C, and a high-temperature residual carbon content of less than 0.55% at 600°C. High-temperature residual carbon content refers to the mass percentage of charred black residue formed after organic matter undergoes thermal evaporation, pyrolysis, and combustion under specific high-temperature conditions; it reflects the carbonaceous composition remaining after the substance decomposes at high temperatures.

[0070] The pore simulation agent of this application has an extremely low residual carbon content, so it will not cause other defects on the glaze. During the high-temperature drying process of ceramic slabs and large ceramic plates, most of the pore simulation agent has volatilized or partially burned and decomposed, leaving pores in the end.

[0071] This application also provides a method for preparing the pore-simulating agent as described above, the method comprising:

[0072] Step A10: Weigh out 0-15 parts by weight of urea and / or liquid paraffin, 10-30 parts by weight of production powder, and 55-75 parts by weight of special solid low-carbon fuel pellets, and mix them to form a powder.

[0073] Step A20: Press the dough into thin cakes using a double-roll mill;

[0074] Step A30: After the thin cake is crushed, it is sieved through a 30-50 mesh sieve to form solid powder particles, which are then used as pore simulation generating agents.

[0075] Specifically, in step A10, after weighing and mixing all the raw materials in the formula, the mixture should be able to be kneaded into a ball without crumbling, and the overall moisture content should be controlled between 1% and 3%. In step A20, the mixture is conveyed by a conveyor belt to a small double-roll mill to form a thin cake. In step A30, after being crushed by a crusher or manually, the cake is sieved through a 30-50 mesh screen to obtain solid powder particles without a fixed shape for later use. The technical characteristics of the solid powder particles are: particle size 6-50 mesh.

[0076] The hole simulation generator in this application is a solid powder particle without a fixed shape. It is made by adding special solid low-carbon fuel particles and mixing it with some of the production powder, rolling it with rollers, granulating and crushing it. It has an extremely low residual carbon content, which will not cause other defects on the glaze surface. Moreover, it is a solid powder particle, which makes it less likely to drift, separate or separate in the digital cloth feeder, thus improving the success rate of hole formation.

[0077] This application also provides a method for preparing a ceramic plate, wherein the method for preparing the ceramic plate includes:

[0078] Step B10: Obtain the pre-prepared base material, and mix the base material with the hole simulation generating agent as described above to obtain the base texture powder;

[0079] Step B20: According to the preset digital fabric process requirements, add the base texture powder into the corresponding material tank of the through-body digital fabric applicator, and first perform reverse digital fabric application on the steel strip of the through-body digital fabric applicator to form a base material layer;

[0080] Step B30: Obtain the pre-prepared fabric, lay the fabric on the base layer to form a fabric layer, and obtain a ceramic blank after drying; the ceramic blank is then processed and fired.

[0081] During the drying process, the pore-simulating agent is burned and volatilized or decomposed into gas to form pores in the substrate layer; during the firing process, the residual carbon after the pore-simulating agent is burned completely, and finally a ceramic plate with pore back texture structure is obtained.

[0082] Specifically, in step B10, after wet milling according to the preset formula process, spray granulation is performed to obtain a base material. The base material is mixed with the pore simulation agent in different proportions to obtain the base texture powder for the full-body digital fabric applicator. In step B20, the powder is added to the corresponding material tank of the full-body digital fabric applicator according to the digital fabric application process requirements, and reverse digital fabric application is first performed on the steel strip to form a base material layer 100, such as... Figure 1As shown. In step B30, a fabric layer is laid on the base layer 100 to form a fabric layer 200; in step B40, the ceramic body is processed according to conventional production process requirements. During the drying and firing process, the pore simulation agent volatilizes or decomposes into gas to form pores 110 in the base layer 100.

[0083] In one embodiment, the raw material formulas of the surface layer and the base layer are the same to eliminate the material performance differences caused by different raw material compositions and prevent the brick from delaminating and deforming.

[0084] This application embodiment uses the v-nature full-body digital fabric system, which lays a base layer and a fabric layer in sequence. The base layer uses a set of pre-designed multi-tube digital powder fabrication mechanisms that can lay a layer of production powder of a specific thickness mixed with a pore simulation generating agent on the surface of the pressed steel strip. The mass of the pore simulation generating agent accounts for 0.5-3% of the total mass of the base layer.

[0085] Specifically, when ceramic slabs or large ceramic slabs are pressed and formed, they are formed by roller pressing. When laying the material, a base layer is first laid digitally using a whole-body digital material laying system, then a surface layer is laid, and then the ceramic slab is made through the conventional slab or large ceramic slab process.

[0086] The ceramic slab of this invention uses digital fabrication to lay the base layer according to a preset texture by a full-body digital fabrication machine. Because some of the powder contains a pore-simulating agent, after high-temperature drying, this agent undergoes physicochemical changes to naturally form irregular isolated pores, through-holes, or groove structures. After firing and stabilization, these structures serve as the back texture of the ceramic slab or large ceramic tile. The multi-tube digital fabrication method achieves flexible and diverse patterns, overcoming the limitations of traditional molding for back texture patterns. Furthermore, the travertine structure cross-section or projection formed by the pore-simulating agent is irregular. Compared to other methods such as mold forming or adhesive bonding to obtain a smooth back texture, this significantly reduces the probability of the ceramic slab / large tile falling off during subsequent installation and bonding, solving the problem of easy detachment when using traditional concrete mortar or tile adhesive in later installation processes.

[0087] In one embodiment, the height ratio of the fabric layer to the base layer is (8-9):(1-2). Compared with the embossed mold forming of the back pattern of ceramic tiles, the present invention has a lower requirement for the height ratio of the fabric layer to the base layer because the surface is flat during pressing, and the flexural strength of the tile will not be reduced due to the density difference of the embossed parts.

[0088] In this embodiment of the application, a surface layer is laid on the base material layer, and a ceramic body is obtained after drying, comprising:

[0089] A fabric layer is laid on the base material layer, and the material is dried at a drying temperature of 150-330℃ for a drying time of 65-95 minutes to obtain a ceramic body.

[0090] Specifically, in this application, within a temperature range of 150-330℃, the moisture in the green body gradually evaporates, the pores between particles decrease, and the structure becomes more compact. The drying time of 65-95 minutes allows the moisture to be fully and evenly discharged, avoiding insufficient or excessive drying.

[0091] This application reduces defects such as cracks and bubbles in the green body and improves product quality by drying at a temperature of 150-330℃ and a drying time of 65-95 minutes.

[0092] In one embodiment of this application, the firing temperature of the ceramic body is 1150-1220℃, and the firing time is 45-85 minutes.

[0093] In this embodiment, at a temperature of 1150-1220℃, sufficient solid-phase reaction and liquid-phase sintering occur between ceramic particles, resulting in a tighter particle bond and a more stable crystal phase structure in the ceramic. This makes it less prone to reacting with chemicals such as acids and alkalis, thus improving its resistance to chemical corrosion. The firing time of 45-85 minutes ensures the firing effect, improves production efficiency, and reduces production costs.

[0094] This application achieves the following effects:

[0095] First, a highly cost-effective solution is used to improve the problem of ceramic slabs and large slabs easily falling off during wall installation, improving the aesthetics and safety of buildings, increasing the possibility of using traditional concrete mortar for slab and large slab installation, and reducing subsequent installation costs.

[0096] Secondly, the pore-simulating agent has a residual carbon content of less than 0.55% at around 600℃, exists in solid form below 60℃, and has a melting or ignition point of 120-130℃. Above 150℃, most of it volatilizes or decomposes through combustion. The residual carbon portion can also be completely burned at around 600℃ during later firing, resulting in extremely low residual carbon content and thus avoiding other defects on the glaze surface. The pore-simulating agent has largely volatilized or decomposed during the high-temperature drying process of ceramic slabs and large ceramic plates, meaning that pores are essentially formed during the drying process; the pore effect is as follows... Figure 2 , Figure 3 and Figure 4 As shown.

[0097] Third, the full-body digital fabric mechanism is a pre-set equipment station of the roll forming equipment, so no additional equipment investment is required.

[0098] Fourth, this invention employs a processing method combining fabric application and hole formation. The hole-simulating agent powder and the base material are mixed and directly applied to the bottom layer. The hole-simulating agent undergoes high-temperature drying and self-ignition, forming irregular isolated holes, through holes, or groove structures through physicochemical changes. This serves as the back texture for ceramic slabs and large ceramic tiles, improving the structure of the slab / tile base and allowing it to fully bond with the concrete mortar during installation. Furthermore, it forms barbs, making it less prone to detachment. This method can replace traditional molding back texture processes, is low-cost, and easy to promote.

[0099] This application also provides a ceramic plate, which is prepared by the ceramic plate preparation method described above.

[0100] This invention provides a pore-simulating agent and its preparation method, as well as a ceramic plate and its preparation method. The pore-simulating agent is added to the base layer of the ceramic plate. The raw material formula of the pore-simulating agent, by weight, includes: 0-15 parts of urea and / or liquid paraffin, 10-30 parts of production powder, and 55-75 parts of specially made solid low-carbon fuel particles. This application uses a pore-simulating agent prepared by using urea and / or liquid paraffin, production powder, and specially made solid low-carbon fuel particles. The residual carbon content of urea and liquid paraffin is low, and they are easily and completely burned and decomposed. Therefore, it can solve the problem that existing pore-forming agents have too high residual carbon content, cannot volatilize quickly after high-temperature firing, and easily cause a large number of glaze defects.

[0101] It should be understood that the application of the present invention is not limited to the examples above. Those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

Claims

1. A pore simulation generating agent for adding to a base material layer of a ceramic plate, characterized by, The raw material formulation of the pore-simulating agent, by weight, includes: 0-15 parts urea and / or liquid paraffin, 10-30 parts production powder, and 55-75 parts special solid low-carbon fuel pellets; The raw material formula of the specially formulated solid low-carbon fuel pellets, by weight, includes: Industrial alcohol 90-95 parts, pearl cotton powder 30-40 parts, stearic acid 4.6-6.6 parts, sodium hydroxide 1.0-1.2 parts, water 4-4.5 parts; The preparation steps of the specially made solid low-carbon fuel pellets include: Stearic acid was added to industrial alcohol, and the mixture was heated and stirred in a water bath until homogeneous to obtain the first mixture. Pearl cotton powder is added to the first mixture, heated and stirred in a water bath until uniform, to obtain the second mixture. Sodium hydroxide was dissolved in water and shaken thoroughly to obtain the third mixture. Industrial alcohol was added to the third mixture, and the mixture was heated and stirred in a water bath until it was homogeneous, thus obtaining the fourth mixture. The fourth mixture is added to the second mixture, heated and stirred in a water bath, and then cooled and solidified naturally to obtain a solidified product. The solidified material is cut into specially made solid low-carbon fuel particles.

2. The pore-simulating agent according to claim 1, characterized in that, The chemical composition of the production powder, by mass percentage, includes: Loss on ignition 4-6%, SiO2 64-70%, Al2O3 20-22%, Fe2O3 0.1-0.3%, CaO 1-3%, MgO 1-3%, K2O 1-3%, Na2O 1-5%, Li2O 0-0.5%.

3. The pore-simulating agent according to claim 1, characterized in that, The pore simulation agent exists in solid form at temperatures below 60°C, has a melting point or ignition point of 120-130°C, and a high-temperature residual carbon content of less than 0.55% at 600°C.

4. A method for preparing a pore-simulating agent as described in any one of claims 1 to 3, characterized in that, The method includes: Weigh out 0-15 parts of urea and / or liquid paraffin, 10-30 parts of production powder, and 55-75 parts of special solid low-carbon fuel pellets by weight, and mix them to form a powder. The dough is pressed into thin cakes using a double-roll mill. After the thin cake is crushed, it is sieved through a 30-50 mesh sieve to form solid powder particles, which are then used as pore-simulating agents.

5. A method for preparing a ceramic plate, characterized in that, The method for preparing the ceramic plate includes: Obtain a pre-prepared base material, and mix the base material with the pore simulation generating agent as described in any one of claims 1 to 3 to obtain a texture powder; According to the preset digital fabric process requirements, the base texture powder is added to the corresponding material tank of the through-body digital fabricer, and the digital fabric is first reverse-blown on the steel strip of the through-body digital fabricer to form a base material layer. A pre-prepared fabric is obtained, and the fabric is laid on the base layer to form a fabric layer. After drying, a ceramic blank is obtained, and the ceramic blank is processed and then fired. During the drying process, the pore-simulating agent is burned and volatilized or decomposed into gas to form pores in the substrate layer; during the firing process, the residual carbon after the pore-simulating agent is burned completely, and finally a ceramic plate with pore back texture structure is obtained.

6. The method for preparing a ceramic plate according to claim 5, characterized in that, A fabric layer is laid on the base material layer, and after drying, a ceramic body is obtained, comprising: A fabric layer is laid on the base material layer, and the material is dried at a drying temperature of 150-330℃ for a drying time of 65-95 minutes to obtain a ceramic body.

7. The method for preparing a ceramic plate according to claim 5, characterized in that, The firing temperature of the ceramic blank is 1150-1220℃, and the firing time is 45-85 minutes.

8. A ceramic plate, characterized in that, The ceramic plate is prepared by the ceramic plate preparation method according to any one of claims 5 to 7.

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