A jade-colored luxury stone effect ceramic rock plate and a preparation method thereof

Abstract

The application discloses a kind of jade color seepage luxury stone effect ceramic rock plate and preparation method thereof, the ceramic rock plate includes body, transparent face glaze layer, jade texture pattern layer, composite dry particle layer, first protective glaze layer, transparent dry particle layer and second protective glaze layer in turn from bottom to top;The raw material components of preparation composite dry particle layer include seepage color dry particle and transmittance dry particle, and the raw material components of seepage color dry particle include by weight 65-69 parts of zircon, 5-7 parts of lithium mica, 10-15 parts of opal, 3-5 parts of kyanite and 1-5 parts of calcium-aluminium garnet;The raw material components of transmittance dry particle include by weight 20-25 parts of sodium feldspar, 25-30 parts of quartz, 14-16 parts of calcite, 8-12 parts of wollastonite and 13.5-15.5 parts of zinc oxide.The ceramic rock plate can truly restore the randomness, level and multicolor interweaving effect of jade color seepage, improve the warm and moist texture and natural luster of product surface, realize the luxury stone effect of jade color seepage.

Description

Technical Field

[0001] This invention belongs to the field of architectural ceramics technology, specifically relating to a ceramic slab with a jade-like patina and its preparation method. Background Technology

[0002] Jade colors are classified into primary and secondary colors based on their formation mechanism. Primary colors are determined by internal metallic elements and color-causing ions, and usually appear as a single color (such as white jade and jasper). Secondary colors, also known as infiltration colors, are penetrating color layers formed after the jade's formation due to environmental factors such as soil minerals, moisture, and temperature. They exhibit a gradual change from the surface inwards and a randomness. The formation of infiltration colors requires a long time (usually tens of thousands of years or more), and the infiltration effect of each piece of jade is unique and cannot be replicated. For example, the infiltration color of Hetian jade pebbles often presents a unique texture with interwoven yellow, red, and black colors. At the same time, the texture of jade is diverse, formed by processes such as crystal growth and fissure filling during geological processes, exhibiting natural and smooth fractal characteristics (self-similar fractal dimension 1.7-1.9). For example, the fibrous interwoven structure of Hetian jade forms a delicate and warm texture, while the granular structure of jadeite produces a lively and varied "jadeite texture." Because the formation of jade requires specific geological conditions and a long time, the resources are extremely scarce. For example, the annual output of Hetian jade pebbles is less than 200 tons, and the rate of high-quality products is less than 5%. Furthermore, over-mining can easily lead to ecological damage and safety hazards. In addition, jade processing requires precise steps such as cutting, carving, and polishing; any mistake in any step can result in a loss of value. Therefore, ceramic slabs with a jade-like luxury stone effect have emerged.

[0003] Currently, existing ceramic slabs still fall short in mimicking the effect of jade, failing to accurately reproduce the patina and texture of jade, and exhibiting certain differences in texture and visual appeal compared to natural jade. Specifically, this manifests in the following two aspects:

[0004] First, the reproduction of color and texture is low. Traditional glaze systems are prone to color deviation (ΔE≥3.5) when the coloring substances (such as iron and copper oxides) are fired above 1200℃, and the color gamut coverage only reaches 60% of natural jade (based on CIELAB spatial analysis). For example, when imitating the white of Hetian jade, it easily turns yellowish (ΔE=2.8), and the green of emerald often has excessive saturation (saturation deviation>20%). At the same time, the patina requires a random distribution of multiple color layers, but the existing dry particle application process can only achieve a color overlap rate of <40%, and lacks the gradual transition from the surface to the interior. Because the patina is a complex effect of multiple color mixtures, and has randomness and unreproducibility, it is difficult for ceramic slabs to achieve this effect with existing technology. For example, to imitate the interwoven yellow, red, and black patina of Hetian jade pebbles, ceramic slabs often only present a blurry color transition, failing to reflect the layering and richness of the patina. Regarding texture, existing digital printing technology is limited by resolution (usually ≤600dpi) and cannot reproduce the 0.1mm-level micro-crack texture of natural jade. Although some ceramic slabs can imitate the texture of jade through printing, carving, and other techniques, these textures often appear stiff and unnatural. For example, when imitating the delicate and warm texture of Hetian jade, ceramic slabs may exhibit a rough texture and lack of depth; when imitating the lively and varied texture of jadeite, ceramic slabs may appear rigid and disjointed. This is because the texture of ceramic slabs is artificially created and cannot possess the naturally grown texture characteristics of natural jade.

[0005] Secondly, the texture and visual effect are inferior. Jade possesses a unique texture, such as warmth, delicacy, and luster. The warm touch of jade stems from the diffuse reflection of light by its fibrous interwoven structure (reflectivity curve smoothness reaches 92%), while the glassy phase structure of ceramic slabs (reflectivity > 85%) results in an excessively high proportion of specular reflection, producing a bright metallic luster. Even with surface treatments such as glazing and polishing, the surface roughness (Ra) still reaches 0.8-1.2μm, far exceeding the 0.1-0.3μm of natural jade. The texture of ceramic slabs still appears hard and cold, lacking the softness and warmth of jade. Meanwhile, the luster of jade is also one of its important characteristics. The greasy luster of natural jade (60° gloss level 65-75GU) is determined by its internal crystal structure and light reflection, possessing a unique soft luster. The high-gloss glaze (gloss level > 90 GU) of ceramic slabs is mainly achieved through surface glazing or polishing, often appearing overly bright or glaring, showing a significant difference from the luster of natural jade. Furthermore, from an overall visual perspective, existing ceramic slabs lack the natural beauty and artistic charm of natural jade. The color, texture, and feel of natural jade blend harmoniously, creating a unified visual effect. Ceramic slabs, however, suffer from deficiencies in color, texture, and feel, resulting in a harsh, uncoordinated visual effect that fails to provide aesthetic enjoyment.

[0006] Therefore, there is an urgent need to develop a ceramic slab that can highly reproduce the color and texture of jade, as well as its feel and visual effect, giving it the luxurious effect of natural jade color. Summary of the Invention

[0007] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, the present invention proposes a ceramic slab with a jade-like patina effect and its preparation method. The ceramic slab can realistically reproduce the randomness, layering, and multi-color interweaving effect of jade patina, enhance the warm texture and natural luster of the product surface, and at the same time enhance the slab's stain resistance, wear resistance, and transparency, thus achieving a jade-like patina effect.

[0008] To solve the above-mentioned technical problems, the first aspect of the present invention provides a ceramic slab, which, from bottom to top, comprises a body, a transparent glaze layer, a jade texture pattern layer, a composite dry granule layer, a first protective glaze layer, a transparent dry granule layer, and a second protective glaze layer.

[0009] The raw material components for preparing the composite dry granule layer include color-enhancing dry granules and transparency-enhancing dry granules. The raw material components of the color-enhancing dry granules, by weight, include: 65-69 parts of zircon, 5-7 parts of lepidolite, 10-15 parts of opal, 3-5 parts of kyanite, and 1-5 parts of grossular garnet. The raw material components of the transparency-enhancing dry granules, by weight, include: 20-25 parts of albite, 25-30 parts of quartz, 14-16 parts of calcite, 8-12 parts of wollastonite, and 13.5-15.5 parts of zinc oxide.

[0010] This invention uses high-zirconia-stained dry granules and high-calcium-zinc-enhanced dry granules as raw materials to prepare a composite dry granule layer. The irregular reflection of the high-refractive-index zirconia crystals improves the reflectivity of multicolor light; and the suspension and encapsulation of the high-calcium-zinc low-temperature-enhanced dry granules enhances the color gradation. By layering simulated jade-stained composite dry granules on a primary color base with a jade-textured pattern layer, the limitation of color overlap rate (<40%) in traditional processes can be overcome. Simultaneously, a transparent dry granule layer is placed between the first and second protective glaze layers, forming an alternating superimposed structure. The protective glaze and transparent dry granules co-melt to form a glassy phase, making the surface gloss closer to the natural petroleum grease luster of jade. Furthermore, the double-layer protective glaze structure helps reduce glaze porosity, thereby improving glaze transmittance.

[0011] Specifically, the patina-enhancing dry granules use zircon as the main raw material, with the addition of certain amounts of lepidolite, opal, kyanite, and grossular garnet. This enhances the overall fidelity of the product's patina and texture. Zircon, as the primary source of ZrO2, provides high reflectivity to the glaze, allowing the ceramic slab to exhibit a multi-colored, shimmering effect similar to natural jade under light, greatly improving the realism of the patina. Lepidolite's main component is K2O, with small amounts of associated elements such as rubidium (Rb) and cesium (Cs). These elements play a supporting role in color formation and adjustment, enriching the patina's hue. During firing, the SiO2·nH2O in opal creates tiny pores or voids due to moisture evaporation. These microstructures facilitate light scattering, further enhancing the three-dimensionality and layering of the patina. Kyanite and grossular garnet provide Al2O3 and other components, working synergistically with other raw materials to promote the formation of patina and texture.

[0012] The raw material components of the anti-reflective granules mainly include quartz, low-temperature flux material albite, and high-temperature flux materials calcite and zinc oxide. These components interact during the low-temperature melting process, which not only improves the wear resistance and stain resistance of the product, but also helps to make the color and texture of the product closer to natural jade. Among them, SiO2 is an important component for forming the glass phase. It can make the anti-reflective granules form a uniform glassy substance after melting, filling the gaps and improving the transparency and gloss of the product. CaO and ZnO help to adjust the physical and chemical properties of the glass phase. CaO can reduce the high-temperature viscosity of the glaze, promote melting and diffusion, and allow the anti-reflective granules to better combine with the coloring granules. ZnO has a good fluxing effect, which can reduce the coefficient of expansion of the glaze, improve the thermal stability of the product, and enhance the color of the glaze.

[0013] In some embodiments of the present invention, the chemical composition of the dyed dry granules, by weight percentage, includes: ZrO2 65-69%, SiO2 15-25%, Al2O3 5-10%, R2O 3-7%, CaO+MgO ≤5%; wherein: R2O represents K2O and / or Na2O.

[0014] Specifically, in the glaze granules, ZrO2, with its high reflectivity, lays the foundation for the product to present realistic jade-like glaze colors and textures. Other components work together with ZrO2 to further enhance the jade-like glaze color and texture effects. Among them: SiO2 is an important component in the formation of the glass phase, which can lower the melting point of the granules and promote better melting during firing; Al2O3 can improve the chemical stability and mechanical strength of the granules; R2O, as a flux, can lower the firing temperature of the granules and promote the fusion of the granules with other glaze layers; CaO and MgO can adjust the structure and properties of the glass phase.

[0015] In terms of color formation, SiO2 participates in the formation of the glass phase, allowing various coloring components to be evenly dispersed within it, resulting in a more uniform and natural color. The stable structure of Al2O3 helps maintain the durability of the color, preventing fading or discoloration during subsequent use. The fluxing effect of R2O allows dry particles of different colors to penetrate and fuse with each other at lower temperatures, achieving richer color layers and more natural color transitions, contributing to the multi-colored and naturally transitioned color effect of jade. CaO and MgO can affect the refractive index of the glass phase, working in conjunction with the high reflectivity of ZrO2 to further enhance the reflection effect of multi-colored light, making the color more vibrant and bright.

[0016] In terms of texture formation, SiO2 affects the fluidity and surface tension of the glass phase, helping to form delicate and smooth textures and avoiding problems such as roughness and breakage. Al2O3 helps to enhance the bonding force between dry particles and other layers, allowing the texture to adhere firmly to the surface of the rock slab, making it less prone to falling off or deforming, ensuring the integrity and clarity of the texture, and making the jade texture more textured. R2O helps to improve the fluidity of dry particles, making the texture more natural and smooth during formation, avoiding the phenomenon of stiff and discontinuous textures. CaO and MgO help to refine the crystal structure, making the texture more delicate, improving the simulation of the texture, and making the texture on the surface of the rock slab closer to the texture characteristics of natural jade.

[0017] In some embodiments of the present invention, the particle size range of the dyed dry granules is D95 between 250-300 μm.

[0018] Specifically, appropriately sized infiltration granules allow them to form a certain spatial structure within the product. During the application of these granules, their size provides larger gaps for the anti-reflective granules, facilitating their filling after low-temperature melting and thus creating a complex microstructure. This contributes to achieving unique optical effects and a sense of depth. Simultaneously, appropriately sized high-zirconium infiltration granules can be better dispersed on the ceramic slab surface, simulating the uneven color distribution and blocky characteristics of natural jade infiltration, further enhancing the simulation effect of the infiltration.

[0019] In some embodiments of the present invention, the particle size range of the enhanced permeability dry particles is D95 between 150-250 μm.

[0020] Specifically, this particle size allows the translucent dry particles to fill the gaps between the color-enhancing dry particles after low-temperature melting, forming a stable "suspended" three-dimensional effect. This microstructure not only enhances the visual depth of the product but also affects light propagation. When light passes through the ceramic slab, it undergoes refraction, reflection, and scattering between dry particles of different sizes, simulating the optical effects within natural jade and enhancing the product's translucency.

[0021] In some embodiments of the present invention, the mass ratio of the dyeing dry granules to the brightening dry granules is 1:(0.55-0.65).

[0022] In some embodiments of the present invention, the raw material components for preparing the transparent dry granule layer are the same as those for preparing the transparent dry granules.

[0023] In some embodiments of the present invention, the raw material components for preparing the first protective glaze layer include, by weight: 45-55 parts potassium feldspar, 20-25 parts quartz, 10-15 parts wollastonite, 5-8 parts calcite, 3-5 parts zinc oxide, 2-4 parts aluminum oxide, and 3-5 parts adhesive.

[0024] Specifically, the protective glaze and the anti-reflective dry granules are fused together to form a glassy phase, which not only makes the glaze surface gloss similar to that of natural jade, but also improves the wear resistance and stain resistance of the glaze layer. Potassium feldspar acts as the main flux, melting first during firing to form a glassy phase precursor. Zinc oxide, as a fluxing agent, helps lower the melting temperature of the glaze, promoting liquid phase formation and allowing ion exchange between the protective glaze and the CaO and ZnO in the anti-reflective dry granules, forming an interlocking structure. Quartz and alumina form a stable glassy network structure at high temperatures, fusing with the ZrO2 in the color-enhancing dry granules and the glassy phase of the anti-reflective dry granules, increasing the overall density of the glaze layer. The adhesive increases the viscosity of the slurry during the drying stage, allowing the protective glaze to penetrate into the gaps between the composite dry granules and the transparent dry material; it also decomposes into gas at high temperatures, leaving microchannels for the glassy phase to fill, thereby enhancing interfacial bonding.

[0025] In some embodiments of the present invention, the adhesive is carboxymethyl cellulose or other polymers.

[0026] In some embodiments of the present invention, the raw material components for preparing the second protective glaze layer are the same as those for preparing the first protective glaze layer.

[0027] In some embodiments of the present invention, the transparent glaze layer is made by firing a transparent glaze, which is used to enhance the color effect of the underlying jade texture pattern.

[0028] In some embodiments of the present invention, the transparent glaze is selected from GYS-MY13 high-transparency glaze of Guangdong Daoshi Technology Co., Ltd.

[0029] The ceramic slab of the present invention does not have special requirements for the blank; conventional ceramic slab blanks can be used.

[0030] A second aspect of the present invention provides a method for preparing the above-mentioned ceramic slab, comprising the following steps:

[0031] A transparent glaze is applied sequentially to the surface of the blank, followed by inkjet printing of a jade texture pattern, application of composite dry granules, application of a first protective glaze, application of transparent dry granules, and application of a second protective glaze, forming a transparent glaze layer, a jade texture pattern layer, a composite dry granule layer, a first protective glaze layer, a transparent dry granule layer, and a second protective glaze layer. After drying, the blank is fired in a kiln to obtain the ceramic slab.

[0032] In some embodiments of the present invention, the step of applying composite dry granules is as follows: according to the design requirements of the product, composite dry granules are applied at a predetermined area on the surface of the jade texture pattern layer to form a densely colored area, wherein the application amount of the densely colored area is 200-320 g / m². 2 Then, composite dry granules are randomly applied to non-preset areas to form a color diffusion zone, with an application rate of 20-120 g / m².2 .

[0033] In some embodiments of the present invention, the positioning application is performed using a carved roller or glue.

[0034] In some embodiments of the present invention, the random distribution adopts a swing-like diffusion method.

[0035] Specifically, traditional methods of applying single dry granules (such as spreading or sieving) struggle to precisely control the coloring area and density, resulting in poor layering and insufficient randomness. This invention addresses this by strategically applying a high concentration of composite dry granules to a pre-defined area, creating a densely colored zone with an edge jaggedness of <15% and a texture similarity of 92%. Simultaneously, a low concentration of composite dry granules is applied to non-pre-defined areas to simulate the random diffusion effect of natural coloring.

[0036] In some embodiments of the present invention, the positioning application uses a 40-mesh double-layer sieve, which reduces the error in the uniformity of dry particle distribution and further improves the application accuracy.

[0037] In some embodiments of the present invention, the specific gravity of the first protective glaze is 1.09-1.11 g / cm³. 3 The application rate is 265-285 g / m³. 2 .

[0038] In some embodiments of the present invention, the specific gravity of the second protective glaze is 1.07-1.09 g / cm³. 3 The application rate is 175-195 g / m³. 2 .

[0039] In some embodiments of the present invention, the particle size range of the first protective glaze and the second protective glaze is D95 between 21 and 25 μm.

[0040] In some embodiments of the present invention, the specific gravity of the surface glaze is 1.41-1.43 g / cm³. 3 The application rate is 425-445 g / m³. 2 .

[0041] In some embodiments of the present invention, the jade texture pattern is printed using a four-color + special ink combination to achieve a color gamut coverage of ≥95% (CIE 1976).

[0042] In some embodiments of the present invention, the amount of the transparent dry granular layer applied is 700-750 g / cm³. 3 .

[0043] In some embodiments of the present invention, the maximum firing temperature is 1160-1200°C. This firing temperature ensures that the composite dry granules and the protective glaze are fully melted, while preventing the decomposition of ZrO2 crystals and maintaining high reflectivity.

[0044] In some embodiments of the present invention, the firing cycle is 50-65 minutes.

[0045] Compared with the prior art, the above-described technical solution of the present invention has at least the following technical effects or advantages:

[0046] (1) The present invention uses high zirconium-stained dry particles and high calcium-zinc-reflective dry particles as raw materials to prepare a composite dry particle layer. The irregular reflection of zirconium oxide crystals with high refractive index improves the reflectivity of multicolor light; and the suspension and encapsulation of low-temperature reflective dry particles enhances the sense of color layering, breaking through the limitation of color overlap rate <40% in traditional processes.

[0047] (2) In this invention, a transparent dry granule layer is placed between the first protective glaze layer and the second protective glaze layer to form an alternating superimposed structure. The protective glaze and the transparent dry granules are fused together to form a glass phase, so that the glaze surface has a 60° gloss of 75-85 GU, which matches the natural jade petroleum grease luster (65-75 GU). The surface roughness Ra≤0.3μm, close to the delicate touch of natural jade. The double-layer protective glaze structure helps to reduce the pores of the glaze surface, thereby improving the light transmittance of the glaze surface and achieving the jade-like transparency effect. The glaze surface also has excellent wear resistance and stain resistance.

[0048] (3) The present invention forms a dense area of ​​staining by applying high concentration of composite dry granules in a preset area, which can achieve low edge serration and high texture similarity; at the same time, low concentration of composite dry granules is applied in non-preset areas to simulate the random diffusion effect of natural staining, so as to achieve high-precision staining with ΔE < 1.5. Attached Figure Description

[0049] Figure 1 This is a photograph of the ceramic slab prepared in Example 1 of the present invention.

[0050] Figure 2 This is a photograph of the ceramic slab prepared in Example 2 of the present invention.

[0051] Figure 3 This is a photograph of the ceramic slab prepared in Example 3 of the present invention.

[0052] Figure 4 This is a physical image of the defective portion of the ceramic slab prepared in Comparative Example 1 of the present invention;

[0053] Figure 5 This is a physical image of the defective portion of the ceramic slab prepared in Comparative Example 2 of the present invention;

[0054] Figure 6 This is a physical image of the defective portion of the ceramic slab prepared in Comparative Example 3 of the present invention;

[0055] Figure 7 This is a physical image of the defective portion of the ceramic slab prepared in Comparative Example 4 of the present invention;

[0056] Figure 8 This is a physical image of the defective portion of the ceramic slab prepared in Comparative Example 5 of the present invention;

[0057] Figure 9 This is a physical image of the defective portion of the ceramic slab prepared in Comparative Example 6 of this invention. Detailed Implementation

[0058] The present invention will now be described in detail with reference to embodiments to facilitate understanding of the invention by those skilled in the art. It is particularly important to note that the embodiments are merely illustrative of the invention and should not be construed as limiting the scope of protection of the invention. Non-essential improvements and adjustments made to the invention by those skilled in the art based on the above description should still fall within the scope of protection of the invention. Furthermore, all raw materials mentioned below, unless otherwise specified, are commercially available products; all process steps or preparation methods not mentioned in detail are process steps or preparation methods known to those skilled in the art.

[0059] Example 1: A ceramic slab with a jade-like patina (patterns and textures of Hetian jade pebbles) for a luxurious stone effect.

[0060] A ceramic slab comprises, from bottom to top, a body, a transparent glaze layer, a jade-textured pattern layer, a composite dry granule layer, a first protective glaze layer, a transparent dry granule layer, and a second protective glaze layer.

[0061] Among them, the raw material for preparing the transparent glaze layer is GYS-MY13 high-transparency glaze from Guangdong Daoshi Technology Co., Ltd.

[0062] The raw material components for preparing the composite dry granule layer include coloring dry granules and transparency-enhancing dry granules in a mass ratio of 1:0.6.

[0063] The raw material composition of the dyed dry granules, by weight, includes: 67 parts zircon, 6 parts lepidolite, 12.5 parts opal, 4 parts kyanite, and 1.5 parts grossular garnet; and the particle size range of the dyed dry granules is D95 between 250-300μm.

[0064] The raw material components of the permeability-enhancing dry granules, by weight, include: 23 parts of albite, 28 parts of quartz, 15.5 parts of calcite, 10 parts of wollastonite, and 14.5 parts of zinc oxide; and the particle size range of the permeability-enhancing dry granules is D95 between 150-250μm.

[0065] The raw material composition for preparing the transparent dry granule layer is the same as that for the transparent dry granule.

[0066] The raw material components for preparing the first protective glaze layer include, by weight: 50 parts potassium feldspar, 22 parts quartz, 12 parts wollastonite, 6 parts calcite, 4 parts zinc oxide, 3 parts aluminum oxide, and 4 parts carboxymethyl cellulose.

[0067] The raw material components for preparing the second protective glaze layer are the same as those for preparing the first protective glaze layer.

[0068] The above-mentioned method for preparing ceramic slabs includes the following steps:

[0069] (1) Pretreatment of the green body: The ceramic slab green body (size 1200×2400×6mm) is transported to the drying area of ​​the roller kiln and dried until the moisture content is 0.2%.

[0070] (2) Topcoat spraying: A centrifugal atomizing spray gun with a pressure set to 0.5 MPa is used to spray the high-transparency topcoat with a constant flow pump (flow rate 435 g / m³). 2 The glaze is evenly sprayed onto the surface of the blank to form a transparent glaze layer with a thickness of 85μm.

[0071] (3) Digital inkjet printing: Load the texture pattern file of Hetian jade seed material (resolution 1200dpi), use a combination of four colors + spot color ink (CMYK + light white / light gray), control the ink volume to 18pL / dot, and perform inkjet printing on the surface of the transparent glaze layer to form a jade texture pattern layer.

[0072] (4) Compound dry granule application

[0073] Precise application: Apply composite dry granules to a pre-defined area (densely stained area) using a CNC engraved roller (40 mesh), at a rate of 260 g / m². 2 ; Activate the vacuum suction device to remove excess dry particles from the unadsorbed areas, forming a densely colored area.

[0074] Random application: Evenly spread the compound dry granules in non-pre-defined areas at a rate of 70 g / m². 2 Simulates the natural diffusion of color, the color diffusion area.

[0075] (5) First protective glaze application: Using a curtain-type glaze spraying machine, apply the first protective glaze slurry (specific gravity 1.10 g / cm³) to the sprayer. 3 (Particle size range: D95 between 21-25 μm) at 275 g / m 2 The amount of the coating is evenly sprayed onto the surface of the composite dry granule layer, with a penetration depth of 0.1 mm, forming the first protective glaze layer.

[0076] (6) Application of transparent dry granules: Apply transparent dry granules through a vibrating screen (40 mesh) at a rate of 735 g / m³. 2 This forms a transparent dry granular layer with a thickness of 0.25 mm.

[0077] (7) Second protective glaze application: Using a high-pressure electrostatic spray gun (voltage 60kV), apply the protective glaze slurry (specific gravity 1.08g / cm³). 3 (Particle size range: D95 between 21-25 μm) at 185 g / m 2 Apply a sealed spray to form a second protective glaze layer.

[0078] (8) Firing: First, raise the temperature from room temperature to 900℃ within 30 minutes, then raise the temperature to 1180℃ at a rate of 15℃ / min, hold for 15 minutes, and then force-cool to below 50℃ before taking it out of the furnace.

[0079] (9) Polishing treatment: The surface of the fired ceramic slab is polished using an automatic polishing machine (grit size 1000#).

[0080] Example 2: A ceramic slab with a jade-like patina (golden silk jade texture pattern) for a luxurious stone effect.

[0081] A ceramic slab comprises, from bottom to top, a body, a transparent glaze layer, a jade-textured pattern layer, a composite dry granule layer, a first protective glaze layer, a transparent dry granule layer, and a second protective glaze layer.

[0082] Among them, the raw material for preparing the transparent glaze layer is GYS-MY13 high-transparency glaze from Guangdong Daoshi Technology Co., Ltd.

[0083] The raw material components for preparing the composite dry granule layer include coloring dry granules and transparency-enhancing dry granules in a mass ratio of 1:0.55.

[0084] The raw material composition of the dyed dry granules, by weight, includes: 65 parts zircon, 5 parts lepidolite, 15 parts opal, 3 parts kyanite, and 2 parts grossular garnet; and the particle size range of the dyed dry granules is D95 between 250-300μm.

[0085] The raw material components of the permeability-enhancing dry granules, by weight, include: 25 parts of albite, 30 parts of quartz, 14 parts of calcite, 12 parts of wollastonite, and 13.5 parts of zinc oxide; and the particle size range of the permeability-enhancing dry granules is D95 between 150-250 μm.

[0086] The raw material composition for preparing the transparent dry granule layer is the same as that for the transparent dry granule.

[0087] The raw material components for preparing the first protective glaze layer include, by weight: 45 parts potassium feldspar, 20 parts quartz, 10 parts wollastonite, 5 parts calcite, 3 parts zinc oxide, 2 parts aluminum oxide, and 3 parts carboxymethyl cellulose.

[0088] The raw material components for preparing the second protective glaze layer are the same as those for preparing the first protective glaze layer.

[0089] The above-mentioned method for preparing ceramic slabs includes the following steps:

[0090] (1) Pretreatment of the green body: The ceramic slab green body (size 1200×2400×6mm) is transported to the drying area of ​​the roller kiln and dried until the moisture content is 0.2%.

[0091] (2) Topcoat spraying: A centrifugal atomizing spray gun with a pressure set to 0.5 MPa is used to spray the high-transparency topcoat with a constant flow pump (flow rate 435 g / m³). 2 The glaze is evenly sprayed onto the surface of the blank to form a transparent glaze layer with a thickness of 85μm.

[0092] (3) Digital inkjet printing: Load the gold silk jade texture pattern file (resolution 1200dpi), use a four-color + spot color ink combination (CMYK + white / gold), control the ink volume to 18pL / dot, and perform inkjet printing on the surface of the transparent glaze layer to form a jade texture pattern layer.

[0093] (4) Compound dry granule application

[0094] Precise application: Apply composite dry granules to a pre-defined area (densely stained area) using a CNC engraved roller (40 mesh), at a rate of 260 g / m². 2 ; Activate the vacuum suction device to remove excess dry particles from the unadsorbed areas, forming a densely colored area.

[0095] Random application: Evenly spread the compound dry granules in non-pre-defined areas at a rate of 70 g / m². 2 Simulates the natural diffusion of color, the color diffusion area.

[0096] (5) First protective glaze application: Using a curtain-type glaze spraying machine, apply the first protective glaze slurry (specific gravity 1.10 g / cm³) to the sprayer. 3 (Particle size range: D95, between 21-25 μm) at 175 g / m 2 The amount of the coating is evenly sprayed onto the surface of the composite dry granule layer, with a penetration depth of 0.1 mm, forming the first protective glaze layer.

[0097] (6) Application of transparent dry granules: Apply transparent dry granules through a vibrating screen (40 mesh) at a rate of 735 g / m³. 2 This forms a transparent dry granular layer with a thickness of 0.25 mm.

[0098] (7) Second protective glaze application: Using a high-pressure electrostatic spray gun (voltage 60kV), apply the protective glaze slurry (specific gravity 1.08g / cm³). 3 (Particle size range: D95 between 21-25 μm) at 195 g / m 2 Apply a sealed spray to form a second protective glaze layer.

[0099] (8) Firing: First, raise the temperature from room temperature to 900℃ within 30 minutes, then raise the temperature to 1180℃ at a rate of 15℃ / min, hold for 15 minutes, and then force-cool to below 50℃ before taking it out of the furnace.

[0100] (9) Polishing treatment: The surface of the fired ceramic slab is polished using an automatic polishing machine (grit size 1000#).

[0101] Example 3: A ceramic slab with a jade-like patina (beige jade texture pattern) for a luxurious stone effect.

[0102] A ceramic slab comprises, from bottom to top, a body, a transparent glaze layer, a jade-textured pattern layer, a composite dry granule layer, a first protective glaze layer, a transparent dry granule layer, and a second protective glaze layer.

[0103] Among them, the raw material for preparing the transparent glaze layer is GYS-MY13 high-transparency glaze from Guangdong Daoshi Technology Co., Ltd.

[0104] The raw material components for preparing the composite dry granule layer include coloring dry granules and transparency-enhancing dry granules in a mass ratio of 1:0.65.

[0105] The raw material composition of the dyed dry granules, by weight, includes: 69 parts zircon, 7 parts lepidolite, 10 parts opal, 5 parts kyanite, and 5 parts grossular garnet; and the particle size range of the dyed dry granules is D95 between 250-300μm.

[0106] The raw material components of the permeability-enhancing dry granules, by weight, include: 20 parts of albite, 25 parts of quartz, 16 parts of calcite, 8 parts of wollastonite, and 15.5 parts of zinc oxide; and the particle size range of the permeability-enhancing dry granules is D95 between 150-250μm.

[0107] The raw material composition for preparing the transparent dry granule layer is the same as that for the transparent dry granule.

[0108] The raw material components for preparing the first protective glaze layer include, by weight: 55 parts potassium feldspar, 25 parts quartz, 15 parts wollastonite, 8 parts calcite, 5 parts zinc oxide, 4 parts aluminum oxide, and 5 parts carboxymethyl cellulose.

[0109] The raw material components for preparing the second protective glaze layer are the same as those for preparing the first protective glaze layer.

[0110] The above-mentioned method for preparing ceramic slabs includes the following steps:

[0111] (1) Pretreatment of the green body: The ceramic slab green body (size 1200×2400×6mm) is transported to the drying area of ​​the roller kiln and dried until the moisture content is 0.2%.

[0112] (2) Topcoat spraying: A centrifugal atomizing spray gun with a pressure set to 0.5 MPa is used to spray the high-transparency topcoat with a constant flow pump (flow rate 435 g / m³). 2 The glaze is evenly sprayed onto the surface of the blank to form a transparent glaze layer with a thickness of 85μm.

[0113] (3) Digital inkjet printing: Load the beige jade texture pattern file (resolution 1200dpi), use a four-color + spot color ink combination (CMYK + light gray / brown), control the ink volume to 18pL / dot, and perform inkjet printing on the surface of the transparent glaze layer to form a jade texture pattern layer.

[0114] (4) Compound dry granule application

[0115] Precise application: Apply composite dry granules to a pre-defined area (densely stained area) using a CNC engraved roller (40 mesh), at a rate of 260 g / m². 2 ; Activate the vacuum suction device to remove excess dry particles from the unadsorbed areas, forming a densely colored area.

[0116] Random application: Evenly spread the compound dry granules in non-pre-defined areas at a rate of 70 g / m². 2 Simulates the natural diffusion of color, the color diffusion area.

[0117] (5) First protective glaze application: Using a curtain-type glaze spraying machine, apply the first protective glaze slurry (specific gravity 1.10 g / cm³) to the sprayer. 3 (Particle size range: D95 between 21-25 μm) at 285 g / m 2 The amount of the coating is evenly sprayed onto the surface of the composite dry granule layer, with a penetration depth of 0.1 mm, forming the first protective glaze layer.

[0118] (6) Application of transparent dry granules: Apply transparent dry granules through a vibrating screen (40 mesh) at a rate of 735 g / m³. 2 This forms a transparent dry granular layer with a thickness of 0.25 mm.

[0119] (7) Second protective glaze application: Using a high-pressure electrostatic spray gun (voltage 60kV), apply the protective glaze slurry (specific gravity 1.08g / cm³). 3 (Particle size range: D95, between 21-25 μm) at 175 g / m 2 Apply a sealed spray to form a second protective glaze layer.

[0120] (8) Firing: First, raise the temperature from room temperature to 900℃ within 30 minutes, then raise the temperature to 1180℃ at a rate of 15℃ / min, hold for 15 minutes, and then force-cool to below 50℃ before taking it out of the furnace.

[0121] (9) Polishing treatment: The surface of the fired ceramic slab is polished using an automatic polishing machine (grit size 1000#).

[0122] Comparative Example 1

[0123] The only difference between Comparative Example 1 and Example 1 is that Comparative Example 1 uses a single color-infused dry granule instead of the composite dry granule of Example 1, that is, only color-infused dry granules are used, without adding any transparency-enhancing dry granules.

[0124] Comparative Example 2

[0125] The only difference between Comparative Example 2 and Example 1 is the raw material composition of the dyed dry granules. The raw material composition of the dyed dry granules of Comparative Example 2, by weight, includes: 60 parts of zircon, 7 parts of lepidolite, 12.5 parts of opal, 6 parts of kyanite, and 2.5 parts of grossular garnet.

[0126] Comparative Example 3

[0127] The only difference between Comparative Example 3 and Example 1 is the raw material composition of the permeable dry granules. The raw material composition of the permeable dry granules of Comparative Example 3, by weight, includes: 26 parts of albite, 35 parts of quartz, 10 parts of calcite, 10 parts of wollastonite, and 10 parts of zinc oxide.

[0128] Comparative Example 4

[0129] The only difference between Comparative Example 4 and Example 1 is the particle size range of the enhanced permeability dry granules. The particle size range of the enhanced permeability dry granules in Comparative Example 4 is D95 between 250-300 μm.

[0130] Comparative Example 5

[0131] The only difference between Comparative Example 5 and Example 1 is that the ceramic slab of Comparative Example 5 does not contain a first protective glaze layer.

[0132] Comparative Example 6

[0133] The only difference between Comparative Example 6 and Example 1 is the application method of the composite dry granules. Comparative Example 6 only performs targeted application to form a dense area of ​​color penetration, instead of random application.

[0134] Performance testing

[0135] The ceramic slab samples prepared in Examples 1-3 and Comparative Examples 1-6 were subjected to relevant performance tests and the glaze jade-like effect was observed. The results are shown in Table 1.

[0136] The gloss test was conducted using a 60° gloss meter, in accordance with GB / T 9754-2007 "Determination of 20°, 60° and 85° specular gloss of paint films without metallic pigments".

[0137] ΔE was calculated using a colorimeter (X-Rite MA98, 8mm measuring diameter) based on the CIELAB color space, according to GB / T7771-2008 "Visual colorimetric comparison of varnishes and lacquers". The color difference between the sample and the standard color swatch of natural jade was determined.

[0138] The color overlap rate was determined by observing the color distribution area of ​​the composite dry granule layer using an optical microscope (magnification 50-100x) and calculating the percentage of overlapping area of ​​different color regions using Image-Pro Plus image analysis software.

[0139] Roughness was measured using a surface roughness measuring instrument according to GB / T 1031-2009 "Surface Roughness Parameters and Their Values".

[0140] The wear resistance is tested according to GB / T3810.7-2016 "Determination of Abrasion Resistance of Glazed Ceramic Tile Surface" for grinding amount; the stain resistance is tested according to GB / T3810.14-2016 "Test Methods for Ceramic Tiles Part 14: Determination of Stain Resistance". The stain resistance is divided into grades, with grade 1 indicating the worst stain resistance and grade 5 indicating the best stain resistance.

[0141] Table 1:

[0142]

[0143]

[0144] As shown in Table 1, the ceramic slabs prepared in Examples 1-3 all exhibit a layered and multi-colored effect with jade-like patina. The surface is warm and translucent, breaking through the limitation of traditional processes where the color overlap rate is <40%, with a color overlap rate reaching 82-85%, resulting in a strong sense of color layering. The glaze has a 60° gloss of 75-85 GU, matching the natural jade petroleum grease luster (65-75 GU). The surface roughness Ra <0.3 μm, approaching the delicate touch of natural jade. ΔE <1.5, indicating high-precision patina. Furthermore, the glaze has a wear resistance of up to level 4 and a stain resistance of up to level 5.

[0145] Compared to Example 1, Comparative Example 1 uses only a single coloring dry granule without adding any transparency-enhancing dry granules, which makes it impossible to form a multi-color interweaving, resulting in a low color overlap rate, a single yellowish color, uneven gloss, strong local mirror reflection, a cloudy and opaque glaze, and reduced wear resistance and stain resistance.

[0146] Compared to Example 1, Comparative Example 2 has a lower zircon content in the stained dry particles, which affects color reproduction and glaze reflectivity, resulting in large color difference, rough texture, low and uneven gloss, blurred microcrack structure, and reduced wear resistance and stain resistance.

[0147] Compared to Example 1, Comparative Example 3 had a lower content of calcite and zinc oxide in the raw material components of the brightening dry granules, resulting in insufficient melting of the dry granules. This led to a grainy texture and pores on the glaze surface, a lack of softness in the gloss, and a reduction in wear resistance and stain resistance.

[0148] Compared to Example 1, Comparative Example 4 shows that the particle size of the translucent dry particles is too large, making it impossible to form an ideal "suspended and wrapped" structure with the dyeing dry particles. This results in uneven light scattering, harsh dyeing boundaries, and a lack of gradient layering. Furthermore, the glaze transmittance decreases, and the overall glaze becomes cloudy.

[0149] Compared to Example 1, Comparative Example 5, lacking the first protective glaze layer, exposes the composite dry granule layer, resulting in increased porosity in the glaze layer, pinholes and pits on the glaze surface, unstable gloss due to lack of glass phase support, localized matte spots, a hard texture, and a significant decrease in stain resistance and wear resistance.

[0150] Compared to Example 1, Comparative Example 6, due to the absence of random application and only targeted application, resulted in a concentrated distribution of patina with neat edges, failing to simulate the random diffusion effect of natural patina. Consequently, the texture and patina were disconnected, and the sense of natural diffusion was lost.

[0151] For those skilled in the art, several simple deductions or substitutions can be made without departing from the concept of this invention, without requiring creative effort. Therefore, any simple improvements made to this invention by those skilled in the art based on the disclosure of this invention should be within the scope of protection of this invention. The above embodiments are preferred embodiments of this invention, and all processes similar to this invention and equivalent changes should fall within the scope of protection of this invention.

Claims

1. A ceramic slab, characterized in that, From bottom to top, it includes a body, a transparent glaze layer, a jade texture pattern layer, a composite dry granule layer, a first protective glaze layer, a transparent dry granule layer, and a second protective glaze layer. The raw material components for preparing the composite dry granule layer include color-enhancing dry granules and transparency-enhancing dry granules. The raw material components of the color-enhancing dry granules, by weight, include: 65-69 parts of zircon, 5-7 parts of lepidolite, 10-15 parts of opal, 3-5 parts of kyanite, and 1-5 parts of grossular garnet. The raw material components of the transparency-enhancing dry granules, by weight, include: 20-25 parts of albite, 25-30 parts of quartz, 14-16 parts of calcite, 8-12 parts of wollastonite, and 13.5-15.5 parts of zinc oxide.

2. The ceramic slab according to claim 1, characterized in that, The particle size range of the dyeing dry granules is D95 between 250-300μm; and / or, the particle size range of the brightening dry granules is D95 between 150-250μm.

3. The ceramic slab according to claim 1 or 2, characterized in that, The mass ratio of the dyeing dry granules to the brightening dry granules is 1:(0.55-0.65).

4. The ceramic slab according to claim 1, characterized in that, The raw material components for preparing the transparent dry granule layer are the same as those for preparing the transparent dry granules.

5. The ceramic slab according to claim 1, characterized in that, The raw material components for preparing the first protective glaze layer include, by weight: 45-55 parts potassium feldspar, 20-25 parts quartz, 10-15 parts wollastonite, 5-8 parts calcite, 3-5 parts zinc oxide, 2-4 parts aluminum oxide, and 3-5 parts adhesive.

6. The ceramic slab according to claim 5, characterized in that, The raw material components for preparing the second protective glaze layer are the same as those for preparing the first protective glaze layer.

7. A method for preparing a ceramic slab as described in any one of claims 1-6, characterized in that, Includes the following steps: A transparent glaze is applied sequentially to the surface of the blank, followed by inkjet printing of a jade texture pattern, application of composite dry granules, application of a first protective glaze, application of transparent dry granules, and application of a second protective glaze, forming a transparent glaze layer, a jade texture pattern layer, a composite dry granule layer, a first protective glaze layer, a transparent dry granule layer, and a second protective glaze layer. After drying, the blank is fired in a kiln to obtain the ceramic slab.

8. The method for preparing ceramic slabs according to claim 7, characterized in that, The step of applying the composite dry granules is as follows: according to the product design requirements, composite dry granules are applied to a predetermined area on the surface of the jade texture pattern layer to form a densely colored area. The application amount of the densely colored area is 200-320g / m². 2 Then, composite dry granules are randomly applied to non-preset areas to form a color diffusion zone, with an application rate of 20-120 g / m². 2 .

9. The method for preparing ceramic slabs according to claim 7, characterized in that, The specific gravity of the first protective glaze is 1.09-1.11 g / cm³. 3 The application rate is 265-285 g / m³. 2 ; and / or, the specific gravity of the second protective glaze is 1.07-1.09 g / cm³. 3 The application rate is 175-195 g / m³. 2 .

10. The method for preparing ceramic slabs according to claim 7, characterized in that, The maximum firing temperature is 1160-1200℃; and / or the firing cycle is 50-65 min.

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