Ceramic tile preparation method based on hot melting plastic package dry granule process and ceramic tile

Abstract

The invention provides a ceramic tile preparation method based on a hot melting plastic package dry granule process and a ceramic tile, and the method comprises the following steps: spraying ground coat on the surface of a to-be-treated ceramic body to form a ground coat layer; spraying and printing a color ink decorative pattern on the surface of the ground coat layer, and simultaneously spraying and printing shaping functional ink to form a pattern decorative layer; applying dry particles on the pattern decoration layer to form a dry particle blank surface; and drying the dry particle blank surface, spraying hot melting plastic sealing glaze on the dry particle blank surface, and sintering in a kiln to obtain the ceramic tile. Specific dry particles are combined with the formula of the hot melting plastic packaging glaze. According to the invention, by applying the dry particles and spraying the hot-melt plastic packaging glaze, the dry particles and the hot-melt plastic packaging glaze are combined, so that the problems of white color and poor transparency caused by interaction of ink, the dry particles and glaze in a dark pattern area are effectively improved, and the overall transparency after combination of the dry particles and the hot-melt plastic packaging glaze is enhanced; and the compatible effect of low surface glossiness and good overall color transparency in a deep color area is achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of ceramic production, and particularly relates to a method for preparing a ceramic tile based on a hot melt plastic-sealed dry granule process and a ceramic tile. Background Art

[0002] With the improvement of people's living quality requirements and the development of the building decoration industry, consumers have higher and higher requirements for the surface performance and decorative effects of building ceramic tiles. They not only require good abrasion resistance, hardness and other basic properties, but also expect rich and diverse decorative effects, such as concavity and convexity, three-dimensional sense, high-definition patterns, etc. The hot melt plastic-sealed dry granule process can achieve rich and diverse decorative effects such as concavity and convexity, three-dimensional sense, and high-definition patterns on the surface of ceramic tiles, meeting the needs of consumers for personalized and high-quality decorative materials, and can be widely used in various scenarios such as home decoration and commercial places.

[0003] The hot melt plastic-sealed dry granule process is an organic combination of digital inkjet printing glue technology and dry granule cloth process. By inkjet printing glue to form a specific pattern, then precisely distributing dry granules in the glue area, and then through subsequent processes such as inkjet printing ordinary ink patterns, applying hot melt plastic-sealed glaze, and firing, ceramic tiles with unique decorative effects are produced. The ceramic tiles produced by this process perform excellently in terms of surface three-dimensional sense, relief effect, pattern texture layering and other properties, and can better meet the usage requirements in different environments. Therefore, with the increasing customized demand in the building decoration market, the hot melt plastic-sealed dry granule process can better meet the personalized customization requirements of customers for ceramic tile products. According to the design patterns or ideas provided by customers, unique ceramic tile products can be produced. This process can precisely control the distribution position and dosage of dry granules, realize more complex and delicate pattern designs, and improve production efficiency and product quality.

[0004] However, in the existing hot melt plastic-sealed dry granule process, problems such as color whitening and poor transparency caused by the interaction of ink with dry granules and glaze will occur.

[0005] Therefore, the existing technology has defects and needs to be improved and developed. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide a method for preparing a ceramic tile based on a hot melt plastic-sealed dry granule process and a ceramic tile aiming at the above-mentioned defects of the existing technology, and to solve the problems of color whitening and poor transparency caused by the interaction of ink with dry granules and glaze in the existing hot melt plastic-sealed dry granule process.

[0007] The technical solution adopted by the present invention to solve the technical problem is as follows:

[0008] The first aspect of the embodiments of the present application provides a method for preparing ceramic tiles based on a hot-melt plastic-sealed dry particle process, which includes:

[0009] Spray a bottom glaze on the surface of the ceramic green body to be processed to form a bottom glaze layer;

[0010] Spray color ink decorative patterns on the surface of the bottom glaze layer, and at the same time spray a shaping functional ink to form a pattern decoration layer;

[0011] Apply dry particles on the pattern decoration layer to form a dry particle blank surface;

[0012] Dry the dry particle blank surface, spray a hot-melt plastic-sealed glaze on the dry particle blank surface, and then fire in a kiln to obtain ceramic tiles;

[0013] Among them, the chemical components of the dry particles are calculated by weight percentage, including:

[0014] Loss on ignition 0.05-0.07%, Al2O3 17-21%, SiO2 20-55%, Fe2O3 0.03-0.09%, CaO 12-15%, MgO 0.5-0.8%, K2O 2-3.5%, Na2O 3-4%, TiO2 0.02-0.06%, B2O3 0-0.05%, BaO 0-0.15%, Li2O 0-0.01%, ZnO 4.5-6%, P2O5 0-0.05%, SrO 2-3%;

[0015] The raw materials of the hot-melt plastic-sealed glaze are calculated by weight percentage, including:

[0016] Barium carbonate 3.5-5.0%, calcined talc 0-1.5%, calcite 3-5.5%, kaolin 4.5-8%, albite 8-11%, transparent frit 20-28%, HF08-300 frit powder 45-60%.

[0017] In an implementation manner of the present application, the raw materials of the hot-melt plastic-sealed glaze are calculated by weight percentage, including:

[0018] Barium carbonate 4.5%, calcined talc 1%, calcite 4.5%, kaolin 4.5%, albite 9%, transparent frit 26.5%, HF08-300 frit powder 50%;

[0019] The chemical components of the hot-melt plastic-sealed glaze are calculated by weight percentage, including:

[0020] Loss on ignition 3.84%, Al2O3 15.88%, SiO2 49.33%, Fe2O3 0.12%, CaO 6.42%, MgO 1.78%, K2O 2.46%, Na2O 4.32%, TiO2 0.05%, B2O3 0.12%, BaO 5.39%, ZnO 4.98%, SrO 2.71%, the balance being impurities;

[0021] In an implementation manner of the present application, the chemical components of the albite, by weight percentage, include:

[0022] Loss on ignition 0.53%, Al2O3 18.55%, SiO2 69.06%, Fe2O3 0.11%, CaO 0.36%, MgO 0.09%, K2O 0.15%, Na2O 10.73%, the balance being impurities;

[0023] The chemical components of the transparent frit, by weight percentage, include:

[0024] Loss on ignition 0.64%, Al2O3 14.08%, SiO2 51.71%, Fe2O3 0.18%, CaO 12.61%, MgO 3.02%, K2O 5.27%, Na2O 0.79%, TiO2 0.06%, B2O3 0.43%, BaO 6.24%, ZnO 4.59%, the balance being impurities;

[0025] The chemical components of the HF08-300 frit powder, by weight percentage, include:

[0026] Loss on ignition 0.05%, Al^2O3 17.55%, SiO2 52.96%, Fe2O3 0.09%, CaO 6.03%, MgO 1.28%, K2O 2.05%, Na2O 6.23%, TiO2 0.07%, B2O3 0.02%, BaO 0.47%, ZrO2 0.11%, ZnO 7.50%, SrO 5.40%, the balance being impurities.

[0027] In an implementation manner of the present application, a color ink decorative pattern is spray-printed on the surface of the base glaze layer, and at the same time, a shaping functional ink is spray-printed to form a pattern decorative layer, including:

[0028] A color ink decorative pattern is spray-printed on the surface of the base glaze layer, and at the same time, the shaping spray ink is spray-printed according to the preset spray gray scale and the dry particle shaping pattern to form a pattern decorative layer.

[0029] In an implementation manner of the present application, dry particles are applied on the pattern decorative layer to form a dry particle green body, including:

[0030] Uniformly distribute dry particles on the pattern decoration layer according to a predetermined flow rate, dry particle amount, and bulk density.

[0031] The dry particles in the area corresponding to the dry particle shaping pattern are fixed by the shaping inkjet ink, and the dry particles in the area outside the dry particle shaping pattern are sucked away by an exhaust fan to form a dry particle blank surface with a dry particle shaping pattern.

[0032] In an implementation manner of the present application, the dry particles on the dry particle blank surface are in a planar shape, and the fineness of the dry particles is 80 to 400 mesh.

[0033] In an implementation manner of the present application, the specific gravity of the hot melt plastic-sealed glaze is 1.22 to 1.38; the glaze spraying amount is 306 to 360 g / m 2 .

[0034] In an implementation manner of the present application, dry the dry particle blank surface, spray hot melt plastic-sealed glaze on the dry particle blank surface, and then fire in a kiln to obtain a ceramic tile, including:

[0035] Dry the dry particle blank surface, spray hot melt plastic-sealed glaze on the dry particle blank surface, and then fire in a kiln.

[0036] After grinding the surface of the fired ceramic tile with a stone grinding matte brush, a ceramic tile is obtained.

[0037] In an implementation manner of the present application, the surface glossiness of the ceramic tile is 5.6°, the surface Mohs hardness is 6, the anti-fouling performance is 4, the chemical corrosion resistance is GLA level, and the wear resistance level is 5.

[0038] An embodiment of the second aspect of the present application provides a ceramic tile, wherein the ceramic tile is prepared by the method for preparing a ceramic tile based on a hot melt plastic-sealed dry particle process as described above.

[0039] A method for preparing a ceramic tile based on a hot-melt plastic-sealed dry granule process and the ceramic tile provided by the present invention. The method for preparing a ceramic tile based on a hot-melt plastic-sealed dry granule process includes: applying a base glaze to the surface of a ceramic green body to be treated to form a base glaze layer; spraying color ink to decorate a pattern on the surface of the base glaze layer, and simultaneously spraying a shaping functional ink to form a pattern decoration layer; applying dry granules on the pattern decoration layer to form a dry granule green surface; drying the dry granule green surface, spraying a hot-melt plastic-sealing glaze on the dry granule green surface, and then firing in a kiln to obtain a ceramic tile; wherein, the chemical components of the dry granules are calculated by weight percentage and include: loss on ignition 0.05-0.07%, Al2O3 17-21%, SiO2 20-55%, Fe2O3 0.03-0.09%, CaO 12-15%, MgO 0.5-0.8%, K2O 2-3.5%, Na2O 3-4%, TiO2 0.02-0.06%, B2O3 0-0.05%, BaO 0-0.15%, Li2O 0-0.01%, ZnO 4.5-6%, P2O5 0-0.05%, SrO 2-3%; the raw materials of the hot-melt plastic-sealing glaze are calculated by weight percentage and include: barium carbonate 3.5-5.0%, calcined talc 0-1.5%, calcite 3-5.5%, kaolin 4.5-8%, albite 8-11%, transparent frit 20-28%, HF08-300 frit powder 45-60%. By spraying a shaping functional ink while inkjet printing a pattern decoration on the surface of the base glaze, then applying dry granules and spraying a hot-melt plastic-sealing glaze, and combining the formulations of the dry granules and the hot-melt plastic-sealing glaze, the present invention effectively improves the problems of color whitening and poor transparency caused by the interaction of ink, dry granules and glaze in the dark pattern area, enhances the overall transparency after the combination of the dry granules and the hot-melt plastic-sealing glaze, and achieves a compatible effect of low surface gloss and good overall transparency of the color in the dark area. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] Figure 1 is a flowchart of a preferred embodiment of a method for preparing a ceramic tile based on a hot-melt plastic-sealed dry granule process in the present invention.

[0041] Figure 2 is an 80% gray-scale flaky texture effect diagram of a matte shaping ink in the present invention.

[0042] Figure 3 is a 60% gray-scale linear texture effect diagram of a matte shaping ink in the present invention.

[0043] Figure 4 is a 120% gray-scale irregular texture effect diagram of a bright shaping ink in the present invention.

[0044] Figure 5 is a 180% gray-scale granular texture effect diagram of a bright shaping ink in the present invention.

[0045] Figure 6 It is the 160% gray geometric texture effect diagram of the bright setting ink in the present invention.

[0046] Figure 7 It is the 75% sandstone texture effect diagram of the bright setting ink 60% gray combined with the matte setting ink in the present invention.

[0047] Figure 8 It is the schematic diagram of the black deep color pattern and color card in the present invention.

[0048] Figure 9 It is the SEM electron micrograph of the surface of the hot-melt plastic-sealed glaze in the present invention. Detailed implementation manners

[0049] To make the objectives, technical solutions and advantages of the present invention clearer and more definite, the following further describes the present invention in detail with reference to the accompanying drawings and by way of examples. It should be understood that the specific examples described herein are only used to explain the present invention and are not used to limit the present invention.

[0050] In the prior art hot-melt plastic-sealed dry particle process, the problems of color whitening and poor transparency caused by the interaction between the ink and the dry particles and glaze mainly result from the poor compatibility between the surface properties of the dry particles and the hot-melt plastic-sealed glaze and the ceramic ink. The color expression ability of many deep color pattern decoration areas is average. The glaze with good transparency has a relatively high overall glossiness, while the glaze with low glossiness has poor transparency. For the ceramic tiles used in the hot-melt plastic-sealed dry particle process, the transparency and glossiness of the dry particles and the hot-melt plastic-sealed glaze used are restricted and limited to each other, and the design hierarchy cannot be truly reflected. Especially when used for the decoration of natural stone textures, the surface gloss is too high to conform to the true texture of natural stone, which restricts the color variety and the presentation of decorative beauty of the hot-melt plastic-sealed process products.

[0051] Therefore, the prior art needs to improve the color rendering ability of digital color inks for inkjet decoration patterns under hot-melt plastic-sealed dry particles and glazes. Especially for inks with special colors or effects, it is necessary to develop matching dry particle materials and hot-melt plastic-sealed glazes to achieve richer and more realistic pattern decoration effects.

[0052] In view of the defect that the existing hot-melt plastic-sealed dry granule process has poor compatibility between dry granules, hot-melt plastic-sealed glaze and ceramic ink, resulting in a white color and poor transparency in the dark pattern area, and the glossiness and transparency restrict each other, making it impossible to present an ideal decorative effect. In the present invention, when inkjet printing a pattern decoration on the surface of the bottom glaze, a shaping functional ink is simultaneously sprayed, and then dry granules are applied, hot-melt plastic-sealed glaze is sprayed, and after firing in a kiln, the surface of the finished ceramic tile is lightly brushed and polished, effectively improving the color and transparency problems in the dark pattern area caused by the interaction of ink, dry granules and glaze. The color difference meter detection shows that the ΔE value is significantly reduced from 3.46 to 2.33; the overall transparency after the combination of dry granules and hot-melt plastic-sealed glaze is enhanced. From the microscopic structure of the glaze layer, it can be seen that its particle characteristics are conducive to light propagation, achieving a compatible effect of low surface glossiness (5.6°) and good transparency of the color in the dark area. The dry granules on the surface of the ceramic tile prepared are convex and three-dimensional, and a unique bright and dark reflective contrast decorative effect is formed after polishing, greatly improving the decorative performance and market competitiveness of the product, and having broad application prospects in the field of architectural decoration.

[0053] Please refer to Figure 1 , Figure 1 which is a flow chart of the method for preparing a ceramic tile based on the hot-melt plastic-sealed dry granule process in the present invention. As Figure 1 shown, the method for preparing a ceramic tile based on the hot-melt plastic-sealed dry granule process described in the embodiment of the present invention includes the following steps:

[0054] Step S100: Apply a bottom glaze to the surface of the ceramic blank to be treated to form a bottom glaze layer;

[0055] Step S200: Spray-print a color ink decorative pattern on the surface of the bottom glaze layer, and simultaneously spray-print a shaping functional ink to form a pattern decoration layer;

[0056] Step S300: Apply dry granules on the pattern decoration layer to form a dry granule blank surface; the chemical components of the dry granules are calculated by weight percentage and include: loss on ignition 0.05 - 0.07%, Al2O3 17 - 21%, SiO2 20 - 55%, Fe2O3 0.03 - 0.09%, CaO 12 - 15%, MgO 0.5 - 0.8%, K2O 2 - 3.5%, Na2O 3 - 4%, TiO2 0.02 - 0.06%, B2O3 0 - 0.05%, BaO 0 - 0.15%, Li2O 0 - 0.01%, ZnO 4.5 - 6%, P2O5 0 - 0.05%, SrO 2 - 3%;

[0057] Step S400: Dry the surface of the dry granular blank, spray hot-melt plastic-sealing glaze on the surface of the dry granular blank, and then fire it in a kiln to obtain a ceramic tile. The raw materials of the hot-melt plastic-sealing glaze, by weight percentage, include: barium carbonate 3.5 - 5.0%, calcined talc 0 - 1.5%, calcite 3 - 5.5%, kaolin 4.5 - 8%, albite 8 - 11%, transparent frit 20 - 28%, HF08-300 frit powder 45 - 60%.

[0058] In step S100, conventional powder materials are used. According to the design requirements, a suitable production line and ceramic tile size are selected, and then it is pressed into shape to obtain a ceramic blank. For example, the size of the pressed blank is 600×1200×9 mm, and the forming pressure is 3000 KN. The underglaze used in this application refers to the underglaze known in the current production that can adapt to the used blank. The underglaze application parameters are specific gravity 1.65 - 1.85, and the application amount is 450 - 530 g / m 2 .

[0059] The loss on ignition in the dry granules of the embodiment of the present application is very low, which means that during the firing process, the shrinkage and gas release of the dry granules will be very small, helping to maintain the clarity and stability of the pattern. The contents of Al2O3 and SiO2 in the dry granule formula are relatively high, and these two oxides are the main components for forming the glass phase, which helps to improve the hardness and wear resistance of the glaze surface. At the same time, they can also affect the optical properties of the glaze surface. There are also appropriate amounts of metal oxides in the dry granule formula, such as Fe2O3, TiO2, etc. These oxides not only affect the color of the glaze surface, but also can optimize the transparency and gloss of the glaze surface by adjusting their contents. ZnO plays a role of fluxing and color mixing in the glaze, and appropriate addition helps to improve the transparency and color saturation of the glaze surface. Other trace components such as B2O3, BaO, Li2O, etc., although their contents are very small, have a significant impact on the microstructure and properties of the glaze surface, helping to further enhance the transparency and stability of the glaze surface.

[0060] In the present invention, while inkjet printing a pattern decoration on the surface of the underglaze, a shaping functional ink is sprayed, and then dry granules are applied and hot-melt plastic-sealing glaze is sprayed. The combination of the dry granule and hot-melt plastic-sealing glaze formulations effectively improves the color and transparency problems in the dark pattern area caused by the interaction of ink, dry granules, and glaze, enhances the overall transparency after the combination of dry granules and hot-melt plastic-sealing glaze, and achieves a compatible effect of low surface gloss and good overall transparency of the color in the dark area.

[0061] In the embodiment of the present application, the raw materials of the hot-melt plastic-sealing glaze, by weight percentage, include: barium carbonate 4.5%, calcined talc 1%, calcite 4.5%, kaolin 4.5%, albite 9%, transparent frit 26.5%, HF08-300 frit powder 50%.

[0062] The chemical components of the hot-melt sealing glaze, by weight percentage, include: loss on ignition 3.84%, Al2O3 15.88%, SiO2 49.33%, Fe2O3 0.12%, CaO 6.42%, MgO 1.78%, K2O 2.46%, Na2O 4.32%, TiO2 0.05%, B2O3 0.12%, BaO 5.39%, ZnO 4.98%, SrO 2.71%, and the balance is impurities.

[0063] In the hot-melt sealing glaze of the embodiment of the present application, barium carbonate, calcite, and kaolin provide elements such as calcium, barium, and silicon in the glaze, which helps to form a stable glass-phase structure; albite and frit are important fluxes in the glaze, which can reduce the melting point of the glaze, promote the melting and flow of the glaze, and thus enhance the gloss and transparency of the glaze surface; HF08-300 frit powder helps to further optimize the transparency and color performance of the glaze surface.

[0064] In an embodiment of the present application, the chemical components of the albite, by weight percentage, include: loss on ignition 0.53%, Al2O3 18.55%, SiO2 69.06%, Fe2O3 0.11%, CaO 0.36%, MgO 0.09%, K2O 0.15%, Na2O 10.73%, and the balance is impurities.

[0065] The chemical components of the transparent frit, by weight percentage, include: loss on ignition 0.64%, Al2O3 14.08%, SiO2 51.71%, Fe2O3 0.18%, CaO 12.61%, MgO 3.02%, K2O 5.27%, Na2O 0.79%, TiO2 0.06%, B2O3 0.43%, BaO 6.24%, ZnO 4.59%, and the balance is impurities.

[0066] The chemical components of the HF08-300 frit powder, by weight percentage, include: loss on ignition 0.05%, Al2O3 17.55%, SiO2 52.96%, Fe2O3 0.09%, CaO 6.03%, MgO 1.28%, K2O 2.05%, Na2O 6.23%, TiO2 0.07%, B2O3 0.02%, BaO 0.47%, ZrO2 0.11%, ZnO 7.50%, SrO 5.40%, and the balance is impurities.

[0067] The hot melt sealing process is a packaging technology based on the property that thermoplastic plastic films soften and become sticky when heated to a specific temperature. The item to be sealed is placed between two plastic films, and through heating and pressing, the films soften and tightly wrap the item. Then, through cooling, the films harden, finally forming a sealed protective package. This technology is widely used in protecting and packaging items such as documents, photos, and cards.

[0068] The hot melt sealing process described in this invention draws on the hot melt sealing process in the field of packaging technology and applies it to building ceramic tiles. The hot melt sealing process for building ceramic tiles is a new technology applied in the production process of building ceramic tiles. Its principle is to use a functional shaping glue with specific viscosity and fluidity to form a uniform glue layer on the surface of the ceramic tile blank for precise positioning and bonding, enabling dry particles with different characteristics to be evenly spread and fixed in corresponding positions through physical and chemical actions. Subsequently, through processes such as drying and curing, glaze sealing (covering the surface with a transparent glaze slurry), and high-temperature firing, a process to enhance the decoration or function of the ceramic tile is ultimately achieved. The transparent glaze slurry covered on the surface melts at high temperature and combines with the dry particle layer, penetrating each other, similar to the process of heating and softening a thermoplastic plastic film, thermally sealing specific dry particles and decorative patterns between the transparent glaze slurry and the base glaze layer.

[0069] In the embodiment of this application, the hot melt sealing glaze albite has relatively high contents of SiO2 and Al2O3, and also contains a certain amount of K2O and Na2O. These components help to reduce the melting point of the glaze, promote the melting and flow of the glaze; after melting, albite can form a smooth and dense glaze surface, and the components in albite help to stabilize the color of the glaze surface and reduce color changes caused by chemical reactions during the firing process. A variety of oxides (such as SiO2, Al2O3, CaO, MgO, K2O, Na2O, etc.) in the transparent frit jointly act on the melting and color adjustment process of the glaze, making the glaze surface have richer colors and better transparency. The components of various oxides in the HF08-300 frit powder are carefully proportioned to optimize the properties such as gloss, hardness, and wear resistance of the glaze surface.

[0070] In the embodiment of this application, the specific step S200 is as follows: Spraying color ink decorative patterns on the surface of the base glaze layer, and at the same time, spraying shaping ink according to the preset spraying gray scale and dry particle shaping pattern to form a pattern decoration layer.

[0071] Specifically, according to the conventional inkjet printing parameters, there are many types of decorative patterns designed, such as stone patterns, granite patterns, geometric patterns, fabric patterns, antique patterns, etc. The decorative patterns can be dot-shaped, line-shaped, sheet-shaped, cluster-shaped, irregular-shaped, etc.

[0072] When the color ink decoration pattern is printed in the embodiment of the present application, the shaping functional ink is printed simultaneously. The shaping functional ink has good viscosity. When the printing amount is large, the viscosity ability is strong, and when the printing amount is small, the viscosity ability will weaken. According to the requirements of the design pattern, the printed shaping functional ink has a certain fixed pattern texture. According to the three-dimensional effect to be expressed, the printing gray scale can be set. The printing gray scale setting range of the single-channel shaping functional ink is 0-100%. The higher the gray scale, the larger the printing amount and the stronger the viscosity. On the contrary, the smaller the printing amount, the weaker the viscosity.

[0073] In addition, the shaping functional ink has a certain firing gloss. According to the strength of the gloss, it can be divided into two categories: bright light and matte. The gloss of the bright light shaping functional ink can reach 60 degrees, while the gloss of the matte shaping functional ink is not higher than 20 degrees.

[0074] In the first embodiment, the shaping ink type is matte, the printing gray scale is 80%, and the shaping pattern is sheet-shaped. The effect diagram is as shown in Figure 2 shown; in the second embodiment, the shaping ink type is matte, the printing gray scale is 60%, and the shaping pattern is linear. The effect diagram is as shown in Figure 3 shown; in the third embodiment, the shaping ink type is bright light, the printing gray scale is 120%, and the shaping pattern is irregular. The effect diagram is as shown in Figure 4 shown; in the fourth embodiment, the shaping ink type is bright light, the printing gray scale is 180%, and the shaping pattern is granular. The effect diagram is as shown in Figure 5 shown; in the fifth embodiment, the shaping ink type is bright light, the printing gray scale is 160%, and the shaping pattern is geometric. The effect diagram is as shown in Figure 6 shown; in the sixth embodiment, the shaping ink type is a combination of bright light and matte, the printing gray scale is 135%, and the shaping pattern is sand-shaped. The effect diagram is as shown in Figure 7 shown.

[0075] In the embodiment of the present application, the step S300 specifically includes:

[0076] Step S310: Uniformly distribute dry particles on the pattern decoration layer according to a predetermined flow rate, dry particle amount, and bulk density;

[0077] Step S320: The dry particles in the area corresponding to the dry particle shaping pattern are fixed by the shaping printing ink, and the dry particles in the area outside the dry particle shaping pattern are sucked away by an exhaust fan to form a dry particle blank surface with a dry particle shaping pattern.

[0078] The dry granules distributed by the dry granulator in this application are special dry granules for ceramic tiles. They are granular substances made by mixing various ceramic raw materials, fluxes and other materials in specific proportions and then through processes such as high-temperature melting, water quenching, crushing, and screening. It has a certain fineness, particle size and specific chemical composition, and is used in ceramic production to achieve different decorative effects and performance improvements. In one embodiment, the dry granulator and the exhaust fan equipment system used in this application are Sepaflight dry granule distributors.

[0079] In one embodiment, the chemical components of the dry granules, by weight percentage, include:

[0080] Loss on ignition 0.05%, Al2O3 18.56%, SiO2 53.10%, Fe2O3 0.09%, CaO 13.89%, MgO 0.72%, K2O 3.01%, Na2O 3.52%, TiO2 0.06%, B2O3 <0.05%, BaO 0.11%, Li2O 0.01%, ZnO 4.66%, P2O5 <0.05%, SrO 2.09%.

[0081] After the dry granules are distributed in this application, the dry granules covering the area printed with the shaping ink will be stuck by the shaping ink and initially fixed, while the dry granules covering the area without printed shaping ink are in a loose state. Under the suction of the exhaust fan, the fine dry granule particles are sucked away by the exhaust fan, and the remaining dry granules that are not sucked away are stuck by the shaping ink. The initially fixed dry granules form the required fixed pattern shape.

[0082] In one embodiment of this application, the dry granules on the surface of the dry granule blank are in a planar shape, and the fineness of the dry granules is 80 - 400 mesh.

[0083] In the embodiment of this application, the particle morphology of the dry granules is rich, mostly irregular granular. The fineness of the dry granules is usually measured by the mesh number, generally between 80 - 400 mesh. Usually, finer dry granules can make the ceramic surface smoother and more delicate, with better gloss and transparency, while coarser dry granules can increase the surface roughness and improve the anti-slip performance. When distributing the dry granules, the amount of dry granules distributed is controlled according to the flow rate of the dry granulator's discharge port. The distributed dry granules are in a planar shape, evenly distributed and covering the blank surface with the printed decorative pattern.

[0084] Examples of dry granule distribution are shown in Table 1:

[0085] Table 1

[0086]

[0087] In the embodiment of this application, the specific gravity of the hot melt plastic-sealed glaze is 1.22 - 1.38; the glaze spraying amount is 306 - 360 g / m 2。

[0088] Specifically, the parameters of the hot-melt plastic-sealed glaze slurry include: the specific gravity is 1.22 to 1.38, the glaze spraying amount is 306 to 360 g / m 2 , and the fluidity is 15 to 18 s. For example, the specific gravity is 1.25, the glaze spraying amount is 322 ± 2 g / m 2 , and the fluidity is 16 ± 1 s.

[0089] In the embodiments of the present application, the specific gravity of the hot-melt plastic-sealed glaze is 1.22 to 1.38. Within this specific gravity range, the hot-melt plastic-sealed glaze has good fluidity, can evenly cover the dry particle green body surface, and form a smooth and dense glaze surface; moreover, the glaze with a moderate specific gravity is not prone to generate bubbles and defects during the firing process, which helps to improve the overall quality of the ceramic tile. The glaze spraying amount of the hot-melt plastic-sealed glaze in the embodiments of the present application is 306 to 360 g / m 2 , within this glaze spraying amount range, it can ensure that the glaze surface has an appropriate thickness, neither too thick nor too thin, so as to maintain the uniformity and aesthetics of the glaze surface. The appropriate glaze amount can reduce the risk of cracking caused by uneven shrinkage of the glaze surface during the firing process, and the sufficient glaze amount can ensure the uniform distribution of the color ink and the shaping functional ink in the glaze layer, thereby optimizing the color performance and clarity of the pattern decoration layer.

[0090] In an embodiment of the present application, the step S400 specifically includes:

[0091] Step S410, drying the dry particle green body surface, spraying the hot-melt plastic-sealed glaze on the dry particle green body surface, and then firing in a kiln;

[0092] Step S420, after grinding the surface of the fired ceramic tile with a stone grinding matte brush, obtaining the ceramic tile.

[0093] Specifically, after the dry particles are adhered by the shaping ink and initially fixed, the initially fixed dry particles are dried in a drying kiln. Drying can make the initially fixed dry particle material more stable and the pattern shape more in line with the regular requirements. After preliminary drying, the hot-melt plastic-sealed glaze slurry is sprayed on the surface of the brick blank to further fix the shape of the dry particles.

[0094] The hot-melt plastic-sealed glaze in the embodiments of the present application is fully melted during firing, further fixing the shape of the covered dry particles. Under the high-temperature firing in the kiln, it has a hot-melt plastic-sealing effect on the decorative pattern and dry particles on the surface of the ceramic tile blank, playing a role in protecting the decorative pattern and further fixing the shape of the dry particles. After firing, the surface of the obtained product has protruding and three-dimensional dry particle shapes, good relief effects, and the pattern shape is permanently stable, playing a very good decorative role.

[0095] In the embodiment of the present application, the surface of the fired ceramic tile is brushed with a special stone grinding matte brush, which can make the surface smoother and have a faint glow. Since the raised area of the hot-melt plastic-sealed dry particle pattern is higher and contacts the grinding head brush more and more forcefully, the brightness rubbed out is stronger than that of other parts, forming a decorative effect of light and dark reflection contrast on the surface, which can make the brick surface present a silk satin surface or the water-washed stone effect of artificial treatment process of natural stone. The implementation examples of the grinding head brush combination parameters are shown in Table 2.

[0096] Table 2

[0097] Type Material Quantity Size Mesh number Pressure Frequency Bra shape Silicon carbide + nylon 5 sets of 30 5×15 cm 120 mesh 1000g 68 hz

[0098] In the embodiment of the present application, the surface gloss of the ceramic tile is 5.6°, the surface Mohs hardness is 6, the anti-fouling performance is 4, the chemical corrosion resistance is GLA level, and the wear resistance level is 5.

[0099] Specifically, a color difference meter is used to measure the Lab values of the present invention on dark color inks and make comparisons, as shown in Table 3.

[0100] Table 3

[0101]

[0102] The change of the L value of the black color using the technology of the present invention, as Figure 8 shown, ΔE decreases from 3.46 to 2.33, and the improvement amplitude is about 32.6%, which is significantly better than the original process technology. By comparing the changes of the lightness L values of the original technology black color card, the dry particle area black color card, the hot-melt plastic-sealed glaze color card, and the hot-melt plastic-sealed glaze black color card of the present invention, it shows that the dry particle and hot-melt plastic-sealed glaze technologies of the present invention more meet the performance requirements of the hot-melt plastic-sealed dry particle process products for dark pattern decoration of black categories, and effectively solve the defects of the existing technology.

[0103] The surface gloss of the ceramic tile obtained in the embodiment of the present application is 5.6°, the surface Mohs hardness is 6, the anti-fouling performance is 4, the chemical corrosion resistance is GLA level, and the wear resistance level is 5.

[0104] As Figure 9 shown, it is the SEM electron micrograph of the hot-melt plastic-sealed glaze surface. There are many grooves and depressions on the surface of the SEM electron micrograph sample, and a large number of rectangular strip-shaped and granular particles are distributed. From the morphology and arrangement of the particles, these particles may be polycrystalline structures generated on the surface of the glaze layer during the firing process, and the entire glaze surface looks relatively rough, with large undulations between the particles. This rough surface structure is the reason for the low gloss of the glaze surface.

[0105] The transparency of the glaze layer is related to the particle size, particle agglomeration, pores, cracks, and crystal structure. From the SEM micrographs, it can be observed that the microstructure of the glaze surface consists of particles of different sizes. When the particle size is small and the distribution is relatively uniform, the scattering of light passing through the glaze surface will be reduced, which is beneficial to improving the transparency of the glaze surface. There is no obvious agglomeration in the SEM micrographs, and light can pass through the glaze surface more smoothly. Agglomerates will hinder the propagation of light, resulting in scattering and reflection of light in these areas, thereby reducing the transparency of the glaze surface. However, when the particles are well-dispersed, it is beneficial to improve the transparency; pores and cracks will cause light to refract, reflect, and scatter inside the glaze surface, affecting the linear propagation of light, and thus reducing the transparency of the glaze surface. The SEM micrographs show that the glaze surface structure is relatively dense, without obvious pores and cracks, which also helps to improve the transparency of the glaze surface. When the crystal structure has a relatively regular lattice arrangement, the interference of light during its propagation is small, which is beneficial to improving the transparency. However, it is difficult to directly judge the crystal structure from this SEM micrograph. If the crystal structure is determined to be simple and regular by combining other analysis methods in the future, it can also be used as a factor to explain the good transparency.

[0106] The present invention has achieved the following beneficial effects:

[0107] First, by optimizing the process steps and material formula, the present invention effectively improves the problems of color whitening and poor transparency in the dark pattern area caused by the interaction of ink with dry particles and glaze. The Lab values of the present invention on dark-colored inks are measured using a color difference meter and compared. ΔE is reduced from 3.46 to 2.33, with an improvement rate of approximately 32.6%, which is significantly better than the original process technology, enhancing the decorative effect and quality of the ceramic tile.

[0108] Second, the present invention enhances the overall transparency after the combination of dry particles and hot-melt plastic-sealed glaze. From the analysis of the microstructure of the glaze layer, the particle size is small and the distribution is relatively uniform, there is no obvious agglomeration, few pores and cracks, and the structure is relatively dense, which is beneficial to improving the transparency of the glaze surface, strengthening the decorative performance of the ceramic tile, and enhancing the market competitiveness of the product.

[0109] Third, the present invention achieves a compatible effect of low surface glossiness (the surface glossiness of the obtained ceramic tile is 5.6°) and good overall transparency in the dark area, enabling the ceramic tile to better present the design hierarchy, especially having advantages in the decoration of natural stone textures, meeting the needs of consumers for high-quality and personalized ceramic tile products.

[0110] The present application also provides a ceramic tile, wherein the ceramic tile is prepared by the method for preparing a ceramic tile based on a hot-melt plastic-sealed dry particle process as described above.

[0111] The present invention provides a method for preparing a ceramic tile based on a hot-melt plastic-sealed dry particle process and a ceramic tile. The method for preparing a ceramic tile based on a hot-melt plastic-sealed dry particle process includes: spraying a bottom glaze on the surface of a to-be-treated ceramic green body to form a bottom glaze layer; spraying color ink to decorate a pattern on the surface of the bottom glaze layer, and simultaneously spraying a shaping functional ink to form a pattern decoration layer; distributing dry particles on the pattern decoration layer to form a dry particle green surface; drying the dry particle green surface, spraying a hot-melt plastic-sealed glaze on the dry particle green surface, and then firing in a kiln to obtain a ceramic tile; wherein, the chemical components of the dry particles are calculated by weight percentage and include: loss on ignition 0.05-0.07%, Al2O3 17-21%, SiO2 20-55%, Fe2O3 0.03-0.09%, CaO 12-15%, MgO 0.5-0.8%, K2O 2-3.5%, Na2O 3-4%, TiO2 0.02-0.06%, B2O3 0-0.05%, BaO 0-0.15%, Li2O 0-0.01%, ZnO 4.5-6%, P2O5 0-0.05%, SrO 2-3%; the raw materials of the hot-melt plastic-sealed glaze are calculated by weight percentage and include: barium carbonate 3.5-5.0%, calcined talc 0-1.5%, calcite 3-5.5%, kaolin 4.5-8%, albite 8-11%, frit 20-28%, HF08-300 frit powder 45-60%. By spraying a shaping functional ink while inkjet printing a pattern decoration on the surface of the bottom glaze, then distributing dry particles and spraying a hot-melt plastic-sealed glaze, the combination of the formulas of the dry particles and the hot-melt plastic-sealed glaze effectively improves the problems of color whitening and poor transparency caused by the interaction of ink, dry particles and glaze in the dark pattern area, enhances the overall transparency after the combination of the dry particles and the hot-melt plastic-sealed glaze, and achieves a compatible effect of low surface gloss and good overall transparency of the color in the dark area.

[0112] It should be understood that the application of the present invention is not limited to the above examples. For those of ordinary skill in the art, improvements or transformations can be made according to the above description, and all such improvements and transformations should fall within the protection scope of the appended claims of the present invention.

Claims

1. A method for preparing ceramic tiles based on a hot-melt plastic-sealed dry granule process, characterized in that, Including: Applying a base glaze to the surface of the ceramic green body to be processed to form a base glaze layer; Spraying color ink decorative patterns and simultaneously spraying a shaping functional ink on the surface of the base glaze layer to form a pattern decorative layer; Spreading dry particles on the pattern decorative layer to form a dry particle green surface; Drying the dry particle green surface, spraying a hot-melt plastic sealing glaze on the dry particle green surface, and then firing in a kiln to obtain a ceramic tile; Wherein, the chemical components of the dry particles are calculated by weight percentage and include: Loss on ignition 0.05 - 0.07%, Al2O3 17 - 21%, SiO2 20 - 55%, Fe2O3 0.03 - 0.09%, CaO 12 - 15%, MgO 0.5 - 0.8%, K2O 2 - 3.5%, Na2O 3 - 4%, TiO2 0.02 - 0.06%, B2O3 0 - 0.05%, BaO 0 - 0.15%, Li2O 0 - 0.01%, ZnO 4.5 - 6%, P2O5 0 - 0.05%, SrO 2 - 3%; The raw materials of the hot-melt plastic sealing glaze are calculated by weight percentage and include: Barium carbonate 3.5 - 5.0%, calcined talc 0 - 1.5%, calcite 3 - 5.5%, kaolin 4.5 - 8%, albite 8 - 11%, transparent frit 20 - 28%, HF08 - 300 frit powder 45 - 60%.

2. The method for preparing a ceramic tile based on a hot-melt plastic-sealed dry granule process according to claim 1, wherein The raw materials of the hot-melt plastic sealing glaze are calculated by weight percentage and include: Barium carbonate 4.5%, calcined talc 1%, calcite 4.5%, kaolin 4.5%, albite 9%, transparent frit 26.5%, HF08 - 300 frit powder 50%; The chemical components of the hot-melt plastic sealing glaze are calculated by weight percentage and include: Loss on ignition 3.84%, Al2O3 15.88%, SiO2 49.33%, Fe2O3 0.12%, CaO 6.42%, MgO 1.78%, K2O 2.46%, Na2O 4.32%, TiO2 0.05%, B2O3 0.12%, BaO 5.39%, ZnO 4.98%, SrO 2.71%, and the balance is impurities.

3. The method for preparing a ceramic tile based on a hot-melt plastic-sealed dry granule process according to claim 2, wherein, The chemical components of the albite are calculated by weight percentage and include: Loss on ignition 0.53%, Al2O3 18.55%, SiO2 69.06%, Fe2O3 0.11%, CaO 0.36%, MgO 0.09%, K2O 0.15%, Na2O 10.73%, and the balance is impurities; The chemical components of the transparent frit are calculated by weight percentage and include: Loss on ignition 0.64%, Al2O3 14.08%, SiO2 51.71%, Fe2O3 0.18%, CaO 12.61%, MgO 3.02%, K2O 5.27%, Na2O 0.79%, TiO2 0.06%, B2O3 0.43%, BaO 6.24%, ZnO 4.59%, and the balance is impurities; The chemical components of the HF08 - 300 frit powder are calculated by weight percentage and include: Loss on ignition: 0.05%, Al2O3: 17.55%, SiO2: 52.96%, Fe2O3: 0.09%, CaO: 6.03%, MgO: 1.28%, K2O: 2.05%, Na2O: 6.23%, TiO2: 0.07%, B2O3: 0.02%, BaO: 0.47%, ZrO2: 0.11%, ZnO: 7.50%, SrO: 5.40%, the balance being impurities.

4. The method for preparing a ceramic tile based on a hot melt encapsulation dry granule process according to claim 1, wherein, Print a decorative pattern with color ink on the surface of the base glaze layer, and at the same time print a shaping functional ink to form a pattern decoration layer, including: Print a decorative pattern with color ink on the surface of the base glaze layer, and at the same time print a shaping ink according to the preset printing gray scale and the dry particle shaping pattern to form a pattern decoration layer.

5. The method for preparing a ceramic tile based on a hot-melt plastic-sealed dry granule process according to claim 4, wherein, Apply dry particles on the pattern decoration layer to form a dry particle green body, including: Apply dry particles evenly on the pattern decoration layer according to the predetermined flow rate, dry particle amount and bulk density; The dry particles in the area corresponding to the dry particle shaping pattern are fixed by the shaping printed ink, and the dry particles in the area outside the dry particle shaping pattern are sucked away by an exhaust fan to form a dry particle green body with a dry particle shaping pattern.

6. The method for preparing a ceramic tile based on a hot-melt encapsulation dry granule process according to claim 5, wherein The dry particles on the dry particle green body are in a planar shape, and the fineness of the dry particles is 80 - 400 mesh.

7. The method for preparing ceramic tiles based on the hot-melt plastic-sealed dry granule process according to claim 1, characterized in that, The specific gravity of the hot-melt plastic-sealing glaze is 1.22 to 1.38; the glaze spraying amount is 306 to 360 g / m 2 .

8. The method for preparing a ceramic tile based on a hot-melt plastic-sealed dry granule process according to claim 1, wherein Dry the dry particle green body, spray a hot melt sealing glaze on the dry particle green body, and then fire it in a kiln to obtain a ceramic tile, including: Dry the dry particle green body, spray a hot melt sealing glaze on the dry particle green body, and then fire it in a kiln; After grinding the surface of the fired ceramic tile with a stone grinding matte brush, a ceramic tile is obtained.

9. The method for preparing a ceramic tile based on a hot melt plastic-sealed dry granule process according to claim 1, characterized in that, The surface glossiness of the ceramic tile is 5.6°, the surface Mohs hardness is 6, the stain resistance is 4, the chemical corrosion resistance is GLA level, and the wear resistance level is 5.

10. A ceramic tile, characterized in that, The ceramic tile is prepared by the method for preparing a ceramic tile based on a hot melt sealing dry particle process according to any one of claims 1 - 9.

Images