A high-gloss lightweight glazed tile and its preparation method

Abstract

This application relates to the field of architectural ceramics technology, specifically disclosing a high-gloss lightweight glazed tile and its preparation method. The preparation method is as follows: Step 1, mixing composite high-alumina clay, expanded perlite, nano-zirconia, and graphene, and ball milling to obtain a body powder; Step 2, pressing the body powder into a body, applying a base glaze, inkjet printing, a transition glaze, and a high-transparency wear-resistant glaze to the body to obtain a tile blank; Step 3, drying and firing the tile blank obtained in Step 2, and then performing composite polishing to obtain the high-gloss lightweight glazed tile. The prepared high-gloss lightweight glazed tile not only has a high Mohs hardness but also significant lightweight characteristics, resulting in a substantial reduction in tile weight. It also possesses a high wear resistance and gloss level, effectively resisting scratches and wear during daily use, ensuring that the surface integrity and aesthetics are maintained even after long-term use.

Description

Technical Field

[0001] This application relates to the field of building ceramics preparation technology, and more specifically, it relates to a high-gloss lightweight glazed tile and its preparation method. Background Technology

[0002] With the booming development of the modern building decoration industry, consumers have increasingly stringent performance requirements for building ceramics. As an important category in the building ceramics field, the performance improvement of glazed tiles has become a focus of industry attention. High gloss and lightweight are the two core directions for the current performance optimization of glazed tiles.

[0003] However, the existing technology still has the following key problems: (1) Conventional polished glazed tiles usually have low gloss, insufficient glaze gloss, and the surface of the glaze layer is prone to defects such as micro-pinholes and orange peel texture, resulting in an excessively high proportion of diffuse reflection of light and a rough visual texture; (2) Traditional glazes are mainly composed of zirconium silicate, feldspar, etc. The glaze formula is limited, the melting temperature is high, the low-temperature fluidity is poor, and it is difficult to form a dense and smooth glaze surface; (3) The hardness of the glaze layer is insufficient, the wear resistance and durability of the glaze layer are poor, and it is easy to be scratched by sand and gravel after long-term use, and the gloss is significantly reduced; (4) The difference in the thermal expansion coefficient between the glaze layer and the body causes internal stress to be generated during firing and cooling, which causes micro-cracks and reduces the frost resistance and corrosion resistance; (5) Traditional polished glazed tiles have a high density, which has many drawbacks in high-rise building exterior walls, prefabricated buildings and other scenarios. Although lightweight ceramic tiles have appeared, while achieving lightweight, they often face problems such as reduced strength and glaze defects. Based on the above statements, this application provides a high-gloss lightweight glazed tile and its preparation method, achieving a synergistic improvement in gloss, wear resistance and lightweight. Summary of the Invention

[0004] To address the technical problems mentioned in the background art, this application provides a high-gloss lightweight glazed tile and its preparation method.

[0005] A method for preparing a high-gloss, lightweight glazed tile includes the following preparation steps:

[0006] Step 1: Mix the composite high-alumina mud, expanded perlite, nano-zirconia, and graphene, and ball mill to D. 50 The thickness is 2-3 μm, resulting in green body powder;

[0007] Step 2: Press the body powder into shape to form a body. Apply a base glaze, inkjet printing, transition glaze and high-transparency wear-resistant glaze to the body to obtain a brick body.

[0008] Step 3: Dry and fire the brick blanks obtained in Step 2, and then perform composite polishing to obtain high-gloss lightweight glazed bricks.

[0009] Preferably, the mass ratio of the composite high-aluminum mud, expanded perlite, nano zirconium oxide and graphene in step 1 is 60-75:22-38:1-3:0.5-2.

[0010] Preferably, the composite high-aluminum mud in step 1 is composed of high-aluminum mud and metakaolin with a mass ratio of 8-10:1-3.

[0011] Preferably, the content of A2O3 in the high-aluminum mud in step 1 is 60-80wt%.

[0012] Preferably, the pressure for pressing in step 1 is 30-80MPa, and the pressure holding time is 8-15s.

[0013] Preferably, the raw materials of the base glaze in step 2 include: potassium feldspar 25-35%, nano zirconium oxide 1-3%, SnO2 2-4%, kaolin 5-10%, and the balance is water, and the specific gravity of the base glaze is 1.85-1.95g / cm 3 , and the glaze application amount is 120-180g / m 2 .

[0014] Preferably, the inkjet printing in step 2 adopts any one or a combination of several of the following: oily inkjet, water-based inkjet, roller printing and sunken inkjet.

[0015] Preferably, the thickness of the ink layer in step 2 is 10-30μm, after inkjet printing, drying is carried out at 80-120℃ for 10-15min, and after drying, the ink penetration depth is ≥0.3mm.

[0016] Preferably, the raw materials of the transition glaze in step 2 include: feldspar 15-18%, quartz 18-22%, kaolin 12-18%, zinc oxide 6-9%, aluminum oxide 4-7%, borax 8-11%, and the balance is water, and the specific gravity of the transition glaze is 1.25-1.52g / cm 3 , and the glaze application amount is 80-150g / m 2 .

[0017] Preferably, the raw materials of the high-transparency wear-resistant glaze in step 2 include: frit 20-28%, potassium feldspar 5-12%, calcined talc 10-12%, quartz 10-12%, borosilicate glass powder 15-18%, lanthanum oxide 0.8-1.2%, zinc oxide 4-6%, and the balance is water, and the specific gravity of the high-transparency wear-resistant glaze is 1.35-1.58g / cm 3 , and the glaze application amount is 280-350g / m 2 .

[0018] Preferably, the mineral composition of the frit is: potassium feldspar 25-35%, quartz 20-25%, barium carbonate 10-18%, raw talc 8-15%, and coarse aluminum oxide 15-20%.

[0019] Preferably, the preparation method of the frit in step 2 is as follows: after mixing potassium feldspar, quartz, barium carbonate, raw talc and coarse aluminum oxide, heat at 800-1000℃ for 20-30min, heat to 1300-1500℃, heat for 2-4h, quench after full melting.

[0020] Preferably, the firing in step 3 adopts gradient temperature control: heat to 300-600℃ at a heating rate of 5-8℃ / min, heat for 10-15min, heat to 700-1000℃ at a heating rate of 10-12℃ / min, heat for 20-25min while maintaining the oxygen content in the kiln at 8-12%, heat to 1000-1150℃ at a heating rate of 10-12℃ / min, heat for 20-30min.

[0021] Preferably, the composite polishing process in step 3 is as follows: first, rough polishing is performed using a resin-based elastic polishing block, the polishing amount is 0.05-0.1mm, then diamond grinding is performed, the polishing amount is 0.03-0.05mm, and finally, polishing is performed using a ceramic polishing liquid, the polishing pressure is 0.1-0.2MPa, the polishing liquid flow rate is 50-80mL / min, and the polishing amount is 0.05-0.1mm.

[0022] A high-gloss light-weight glazed tile is prepared by the above method.

[0023] In summary, the present application has the following beneficial effects:

[0024] The present application utilizes high-aluminum mud and metakaolin to form a composite high-aluminum mud, the high-aluminum mud has a high content of alumina, and has high hardness and rigidity itself, which can build a solid skeleton structure for the body, greatly enhancing the compressive strength and deformation resistance of the body. However, when used alone, the high-aluminum mud has coarse particles and high porosity, and needs to rely on a large amount of binder to fill, which may increase the density of the body. By compounding with metakaolin, the nano-sized particles of metakaolin can fill the gaps between high-aluminum mud particles, reduce the internal voids of the body, reduce the amount of aggregate per unit volume while maintaining the integrity of the skeleton structure, thereby achieving lightweight. The pozzolanic activity of metakaolin causes it to react with the glass phase on the surface of expanded perlite during firing, forming a silicate gel transition layer, which improves the bonding force between the light-weight aggregate and the rigid skeleton, and avoids loose structure caused by excessive porosity. The high melting point of high-aluminum mud can limit the excessive expansion of expanded perlite at high temperatures, prevent the density of the body from fluctuating due to pore cracking or merging, and ensure the stability of the structure.

[0025] The application promotes complete decomposition and release of barium carbonate at low temperature in the process of preparing a melt, completely discharges structural water in talc, reduces glaze pores, ensures complete melting at a high temperature section, promotes partial vitrification of the surface of alumina particles, enhances the bonding force with the matrix, quenches the melt, inhibits crystal precipitation, forms a uniform amorphous glass phase, and ensures high transparency of the glaze layer. DETAILED DESCRIPTION

[0026] The application is further described below in combination with examples.

[0027] The high-aluminum clay used in the examples and comparative examples of the application was purchased from Changhui Building Material Supply Station in Economic Development Zone; the expanded perlite was purchased from Lunkun Mineral Product Processing Factory in Lingshou County; the metakaolin (mesh: 800 mesh) was purchased from Dexu Mining Co., Ltd. in Lingshou County; the kaolin was purchased from Bohan Mineral Product Co., Ltd. in Lingshou County; and the ordinary frit (model: YS633 powder) was purchased from Zibo Yishun Ceramic Color Glaze Co., Ltd.

[0028] Examples 1-3 provide a high-gloss light-weight polished glaze brick and a preparation method.

[0029] Example 1

[0030] A preparation method of a high-gloss light-weight polished glaze brick, comprising the following steps:

[0031] Step 1, mixing composite high-aluminum clay, expanded perlite, nano zirconium oxide and graphene according to a mass ratio of 60:22:1:0.5, ball milling to D 50 2 μm to obtain a body powder, wherein the composite high-aluminum clay is composed of high-aluminum clay and metakaolin at a mass ratio of 8:1, and the A2O3 content in the high-aluminum clay is 60 wt%;

[0032] Step 2, pressing the body powder to form a body, applying a base glaze, inkjet printing, transition glaze and high-transparency wear-resistant glaze on the body to obtain a brick body, wherein the base glaze raw materials include: 25% of potassium feldspar, 1% of nano zirconium oxide, 22% of SnO2, 5% of kaolin, and the balance is water, the specific gravity of the base glaze is 1.85 g / cm 3 , the glaze application amount is 120 g / m 2 , the inkjet printing adopts water-based permeable inkjet, the ink layer thickness is 10 μm, after inkjet printing, drying at 80℃ for 10 min, after drying, the ink penetration depth is 0.3 mm, the transition glaze raw materials include: 15% of feldspar, 18% of quartz, 12% of kaolin, 6% of zinc oxide, 4% of alumina and 8% of borax, and the balance is water, the specific gravity of the transition glaze is 1.25 g / cm 3 , the glaze application amount is 80 g / m 2The raw material of the high-transparency wear-resistant glaze comprises: frit 20%, potassium feldspar 5%, calcined talc 10%, quartz 10%, borosilicate glass powder 15%, lanthanum oxide 0.8%, zinc oxide 4%, and the balance is water, and the high-transparency wear-resistant glaze has a specific gravity of 1.35 g / cm 3 The amount of the applied glaze is 280 g / m 2 The mineral composition of the frit comprises: potassium feldspar 35%, quartz 25%, barium carbonate 10%, raw talc 10%, and coarse aluminum oxide 20%; the preparation method of the frit is as follows: the potassium feldspar, the quartz, the barium carbonate, the raw talc and the coarse aluminum oxide are mixed, then the mixture is heated to 800 DEG C and kept for 20 min, then the temperature is increased to 1300 DEG C and kept for 2 h, and then the mixture is quenched to prepare the frit;

[0033] Step 3, the green brick prepared in step 2 is dried at 40 DEG C for 6 h, heated to 300 DEG C at a heating rate of 5 DEG C / min and kept for 10 min, heated to 700 DEG C at a heating rate of 10 DEG C / min and kept for 20 min, while the oxygen content in the kiln is maintained at 8%, heated to 1000 DEG C at a heating rate of 10 DEG C / min and kept for 20 min, then rough polishing is performed by using a resin-based elastic polishing block with a polishing amount of 0.05 mm, then diamond polishing is performed with a polishing amount of 0.03 mm, and finally polishing is performed by using a ceramic polishing liquid with a polishing pressure of 0.1 MPa, a polishing liquid flow rate of 50 mL / min and a polishing amount of 0.05 mm, thereby obtaining the high-gloss light-weight glazed brick.

[0034] Example 2

[0035] Step 1, the composite high-aluminum mud, the expanded perlite, the nano-zirconium oxide and the graphene are mixed according to a mass ratio of 68:30:2:1, ball-milled to a D 50 value of 2.5 mu m, thereby obtaining a green body powder, wherein the composite high-aluminum mud is composed of high-aluminum mud and metakaolin according to a mass ratio of 9:2, and the A2O3 content in the high-aluminum mud is 70 wt%;

[0036] Step 2, the green body powder is subjected to compression molding to form a green body, and then a base glaze, inkjet printing, a transition glaze and a high-transparency wear-resistant glaze are applied to the green body, thereby obtaining a green brick, wherein the base glaze raw material comprises: potassium feldspar 30%, nano-zirconium oxide 2%, SnO2 3%, metakaolin 8%, and the balance is water, and the base glaze has a specific gravity of 1.92 g / cm 3 The amount of the applied glaze is 150 g / m 2 The inkjet printing adopts water-based permeable inkjet, and the ink layer has a thickness of 20 mu m; after the inkjet printing, drying is performed at 100 DEG C for 12 min, and after drying, the ink penetration depth is 0.4 mm; the transition glaze raw material comprises: feldspar 17%, quartz 20%, metakaolin 15%, zinc oxide 7%, aluminum oxide 5% and borax 9%, and the balance is water, and the transition glaze has a specific gravity of 1.38 g / cm 3, the glaze amount is 120g / m 2 The high-transparency wear-resistant glaze raw material comprises: frit 24%, potassium feldspar 8%, calcined talc 11%, quartz 11%, borosilicate glass powder 16%, lanthanum oxide 1%, zinc oxide 5%, and the balance is water, and the high-transparency wear-resistant glaze has a specific gravity of 1.43g / cm 3 , the glaze amount is 300g / m 2 The mineral composition of the frit is: potassium feldspar 32%, quartz 22%, barium carbonate 15%, raw talc 13%, and coarse aluminum oxide 18%; the preparation method of the frit is: after the potassium feldspar, the quartz, the barium carbonate, the raw talc and the coarse aluminum oxide are mixed, the mixture is heated to 900 DEG C and kept for 25 minutes, then the temperature is increased to 1400 DEG C and kept for 3 hours, and after being fully melted, the mixture is quenched to prepare the frit;

[0037] Step 3, the green brick prepared in step 2 is dried at 50 DEG C for 8 hours, heated to 450 DEG C at a heating rate of 6 DEG C / min, kept for 12 minutes, heated to 850 DEG C at a heating rate of 11 DEG C / min, kept for 22 minutes, while maintaining the oxygen content in the kiln at 10%, heated to 1080 DEG C at a heating rate of 11 DEG C / min, kept for 25 minutes, rough polished by using a resin-based elastic grinding block, the polishing amount is 0.08mm, polished by using a diamond grinding sheet, the polishing amount is 0.04mm, and finally polished by using a ceramic polishing liquid, the polishing pressure is 0.15MPa, the polishing liquid flow is 65mL / min, and the polishing amount is 0.08mm, thereby a high-gloss light-weight glazed brick is obtained.

[0038] Example 3

[0039] Step 1, the composite high-aluminum mud, the expanded perlite, the nano-zirconium oxide and the graphene are mixed according to a mass ratio of 75:38:3:2, ball-milled to D 50 =3um, and the green body powder is obtained, wherein the composite high-aluminum mud is composed of high-aluminum mud and metakaolin according to a mass ratio of 10:3, and the A2O3 content in the high-aluminum mud is 80wt%;

[0040] Step 2, the green body powder is pressed and formed, the pressing pressure is 80MPa, and the pressure is kept for 15s, and the green body is obtained, and the bottom glaze, the inkjet printing, the transition glaze and the high-transparency wear-resistant glaze are applied on the green body, thereby the green brick is obtained, wherein the bottom glaze raw material comprises: potassium feldspar 35%, nano-zirconium oxide 3%, SnO2 4%, metakaolin 10%, and the balance is water, the specific gravity of the bottom glaze is 1.95g / cm 3 , the glaze amount is 180g / m 2, the inkjet printing uses water-based permeable inkjet, the ink layer thickness is 30 mu m, after the inkjet printing, drying is carried out at 120 DEG C for 15 min, after drying, the ink penetration depth is 0.5 mm, the transition glaze raw materials include: feldspar 18%, quartz 22%, kaolin 18%, zinc oxide 9%, aluminum oxide 7%, borax 11%, and the balance is water, the specific gravity of the transition glaze is 1.52 g / cm 3 , the glazing amount is 150 g / m 2 , the high-transparency wear-resistant glaze raw materials include: frit 28%, potassium feldspar 12%, calcined talc 12%, quartz 12%, borosilicate glass powder 18%, lanthanum oxide 1.2%, zinc oxide 6%, and the balance is water, the specific gravity of the high-transparency wear-resistant glaze is 1.58 g / cm 3 , the glazing amount is 350 g / m 2 , the mineral composition of the frit is: potassium feldspar 32%, quartz 15%, barium carbonate 18%, raw talc 15%, and coarse aluminum oxide 20%; the preparation method of the frit is: after mixing potassium feldspar, quartz, barium carbonate, raw talc and coarse aluminum oxide, heat treatment is carried out at 1000 DEG C for 30 min, the temperature is increased to 1500 DEG C, and heat preservation is carried out for 4 h, after full melting, quenching is carried out to prepare the frit;

[0041] Step 3, the green brick prepared in step 2 is dried at 60 DEG C for 10 h, heated to 600 DEG C at a heating rate of 8 DEG C / min, heat preservation is carried out for 15 min, heated to 1000 DEG C at a heating rate of 12 DEG C / min, heat preservation is carried out for 25 min, the oxygen content in the kiln is maintained at 12%, heated to 1150 DEG C at a heating rate of 12 DEG C / min, heat preservation is carried out for 30 min, first, rough polishing is carried out by using a resin-based elastic polishing block, the polishing amount is 0.1 mm, then, diamond grinding pieces are used for polishing, the polishing amount is 0.05 mm, finally, polishing is carried out by using a ceramic polishing liquid, the polishing pressure is 0.2 MPa, the polishing liquid flow rate is 80 mL / min, and the polishing amount is 0.1 mm, thereby a high-gloss light-weight polished glaze brick is obtained.

[0042] Comparative example 1

[0043] A preparation method of a high-gloss light-weight polished glaze brick, comprising the following steps:

[0044] Step 1, high-aluminum mud, expanded perlite, nano-zirconium oxide and graphene are mixed according to the mass ratio of 60:22:1:0.5, ball milling is carried out until the D 50 value of the body powder is 2 mu m, wherein the A2O3 content in the high-aluminum mud is 60 wt%;

[0045] Step 2, the green body powder is formed by pressing, the pressing pressure is 30 MPa, the pressure maintaining time is 8 s, the green body is formed, the bottom glaze, inkjet printing, transition glaze and high-transparency wear-resistant glaze are applied on the green body, and the green body is obtained, wherein the raw materials of the bottom glaze include 25% of potassium feldspar, 1% of nano-zirconium oxide, 2% of SnO2 and 5% of kaolin, and the balance is water, the specific gravity of the bottom glaze is 1.85 g / cm 3 , the glaze application amount is 120 g / m 2 , the inkjet printing adopts water-based permeable inkjet, the ink layer thickness is 10 μm, after the inkjet printing, drying is performed at 80 ℃ for 10 min, after drying, the ink penetration depth is 0.3 mm, the raw materials of the transition glaze include 15% of feldspar, 18% of quartz, 12% of kaolin, 6% of zinc oxide and 4% of aluminum oxide, 8% of borax, and the balance is water, the specific gravity of the transition glaze is 1.25 g / cm 3 , the glaze application amount is 80 g / m 2 , the raw materials of the high-transparency wear-resistant glaze include 20% of frit, 5% of potassium feldspar, 10% of calcined talc, 10% of quartz, 15% of borosilicate glass powder, 0.8% of lanthanum oxide and 4% of zinc oxide, and the balance is water, the specific gravity of the high-transparency wear-resistant glaze is 1.35 g / cm 3 , the glaze application amount is 280 g / m 2 , the mineral composition of the frit is 35% of potassium feldspar, 25% of quartz, 10% of barium carbonate, 10% of raw talc and 20% of coarse aluminum oxide, the preparation method of the frit is that the potassium feldspar, the quartz, the barium carbonate, the raw talc and the coarse aluminum oxide are mixed, then the mixture is heated at 800 ℃ for 20 min, the temperature is increased to 1300 ℃, and the mixture is heated at 1300 ℃ for 2 h, and after being fully fused, the frit is prepared by quenching;

[0046] Step 3, the green body obtained in step 2 is dried at 40 ℃ for 6 h, the temperature is increased to 300 ℃ at a temperature increasing rate of 5 ℃ / min, the temperature is maintained for 10 min, the temperature is increased to 700 ℃ at a temperature increasing rate of 10 ℃ / min, the temperature is maintained for 20 min, the oxygen content in the kiln is maintained at 8% at the same time, the temperature is increased to 1000 ℃ at a temperature increasing rate of 10 ℃ / min, the temperature is maintained for 20 min, coarse polishing is performed by using a resin-based elastic abrasive block, the polishing amount is 0.05 mm, diamond abrasive sheet is used for polishing, the polishing amount is 0.03 mm, finally, polishing is performed by using a ceramic polishing liquid, the polishing pressure is 0.1 MPa, the polishing liquid flow is 50 mL / min, and the polishing amount is 0.05 mm, and a high-gloss light-weight polished glaze tile is obtained.

[0047] Comparative Example 2

[0048] A preparation method of a high-gloss light-weight polished glaze tile, comprising the following steps:

[0049] Step 1, composite high-aluminum mud, expanded perlite, nano-zirconium oxide and graphene are mixed according to a mass ratio of 60:22:1:0.5, and ball milling is performed until the D 50is 2 μm, to obtain a green body powder, wherein the composite high-alumina mud is composed of high-alumina mud and kaolin in a mass ratio of 8:1, and the A2O3 content in the high-alumina mud is 60 wt%;

[0050] Step 2, the green body powder is subjected to press forming, the press forming pressure is 30 MPa, and the pressure maintaining time is 8 s, to form a green body, a base glaze, inkjet printing, transition glaze and high-transparency wear-resistant glaze are applied on the green body, to obtain a brick green body, wherein the base glaze raw materials include: potassium feldspar 25%, nano-zirconium oxide 1%, SnO2 22%, kaolin 5%, and the balance is water, the base glaze specific gravity is 1.85 g / cm 3 , the glaze application amount is 120 g / m 2 , the inkjet printing adopts water-based permeable inkjet, the ink layer thickness is 10 μm, after the inkjet printing, drying is performed at 80℃ for 10 min, after drying, the ink penetration depth is 0.3 mm, the transition glaze raw materials include: feldspar 15%, quartz 18%, kaolin 12%, zinc oxide 6%, aluminum oxide 4%, borax 8%, and the balance is water, the transition glaze specific gravity is 1.25 g / cm 3 , the glaze application amount is 80 g / m 2 , the high-transparency wear-resistant glaze raw materials include: frit 20%, potassium feldspar 5%, calcined talc 10%, quartz 10%, borosilicate glass powder 15%, lanthanum oxide 0.8%, zinc oxide 4%, and the balance is water, the high-transparency wear-resistant glaze specific gravity is 1.35 g / cm 3 , the glaze application amount is 280 g / m 2 , the mineral composition of the frit is: potassium feldspar 35%, quartz 25%, barium carbonate 10%, raw talc 10%, and coarse aluminum oxide 20%; the preparation method of the frit is: the potassium feldspar, quartz, barium carbonate, raw talc and coarse aluminum oxide are mixed, then heated at 800℃ for 20 min, heated to 1300℃, and kept for 2 h, and then quenched after full melting to obtain the frit;

[0051] Step 3, the brick green body prepared in step 2 is dried at 40℃ for 6 h, heated to 300℃ at a heating rate of 5℃ / min, kept for 10 min, heated to 700℃ at a heating rate of 10℃ / min, kept for 20 min, while maintaining the oxygen content in the kiln at 8%, heated to 1000℃ at a heating rate of 10℃ / min, kept for 20 min, then subjected to rough polishing with a resin-based elastic polishing block, the polishing amount is 0.05 mm, then subjected to polishing with a diamond grinding sheet, the polishing amount is 0.03 mm, and finally subjected to polishing with a ceramic polishing liquid, the polishing pressure is 0.1 MPa, the polishing liquid flow rate is 50 mL / min, and the polishing amount is 0.05 mm, to obtain a high-gloss light-weight polished glaze brick.

[0052] Comparative Example 3

[0053] A preparation method of a high-gloss light-weight polished glaze brick, comprising the following steps:

[0054] Step 1, the composite high-aluminum mud, expanded perlite, nano zirconium oxide and graphene are mixed according to the mass ratio of 60:22:1:0.5, ball milled to D 50 2 μm, to obtain a green body powder, wherein the composite high-aluminum mud is composed of high-aluminum mud and metakaolin in a mass ratio of 8:1, and the A2O3 content in the high-aluminum mud is 50wt%;

[0055] Step 2, the green body powder is pressed to form a green body, the pressing pressure is 30 MPa, and the pressure holding time is 8 s, the green body is applied with a base glaze, inkjet printing, transition glaze and high-transparency wear-resistant glaze to obtain a brick body, wherein the base glaze raw materials include: potassium feldspar 25%, nano zirconium oxide 1%, SnO2 22%, kaolin 5%, and the balance is water, the specific gravity of the base glaze is 1.85 g / cm 3 , the glaze application amount is 120 g / m 2 , the inkjet printing adopts water-based permeable inkjet, the ink layer thickness is 10 μm, after inkjet printing, drying is carried out at 80℃ for 10 min, after drying, the ink penetration depth is 0.3 mm, the transition glaze raw materials include: feldspar 15%, quartz 18%, kaolin 12%, zinc oxide 6%, alumina 4%, borax 8%, and the balance is water, the specific gravity of the transition glaze is 1.25 g / cm 3 , the glaze application amount is 80 g / m 2 , the high-transparency wear-resistant glaze raw materials include: frit 20%, potassium feldspar 5%, calcined talc 10%, quartz 10%, borosilicate glass powder 15%, lanthanum oxide 0.8%, zinc oxide 4%, and the balance is water, the specific gravity of the high-transparency wear-resistant glaze is 1.35 g / cm 3 , the glaze application amount is 280 g / m 2 , the mineral composition of the frit is: potassium feldspar 35%, quartz 25%, barium carbonate 10%, raw talc 10%, and coarse alumina 20%; the preparation method of the frit is: the potassium feldspar, quartz, barium carbonate, raw talc and coarse alumina are mixed, then heated at 800℃ for 20 min, the temperature is increased to 1300℃, and the temperature is kept for 2 h, after full melting, quenching is carried out to obtain the frit;

[0056] Step 3, the brick body prepared in step 2 is dried at 40℃ for 6 h, heated to 300℃ at a heating rate of 5℃ / min, kept for 10 min, heated to 700℃ at a heating rate of 10℃ / min, kept for 20 min, while maintaining the oxygen content in the kiln at 8%, heated to 1000℃ at a heating rate of 10℃ / min, kept for 20 min, then rough polishing is carried out with a resin-based elastic polishing block, the polishing amount is 0.05 mm, diamond grinding sheet, the polishing amount is 0.03 mm, finally polishing is carried out with a ceramic polishing liquid, the polishing pressure is 0.1 MPa, the polishing liquid flow rate is 50 mL / min, and the polishing amount is 0.05 mm, to obtain a high-gloss light-weight glazed brick.

[0057] Comparative Example 4

[0058] A preparation method of high-gloss light-weight glazed tile, comprising the following steps:

[0059] Step 1, compound high-alumina mud, expanded perlite, nano zirconia and graphene are mixed according to the mass ratio of 60:22:1:0.5, ball-milled to D 50 2μm, to obtain a green body powder, wherein the compound high-alumina mud is composed of high-alumina mud and metakaolin in a mass ratio of 8:1, and the A2O3 content in the high-alumina mud is 60wt%;

[0060] Step 2, the green body powder is pressed and formed, the pressing pressure is 30MPa, the pressure holding time is 8s, to form a green body, a base glaze, inkjet printing, transition glaze and high-transparency wear-resistant glaze are applied on the green body, to obtain a tile body, wherein the base glaze raw materials include: potassium feldspar 25%, nano zirconia 1%, SnO22%, kaolin 5%, and the balance is water, the specific gravity of the base glaze is 1.85g / cm 3 , the glaze application amount is 120g / m 2 , the inkjet printing adopts water-based permeable inkjet, the ink layer thickness is 10μm, after inkjet printing, drying is carried out at 80℃ for 10min, after drying, the ink penetration depth is 0.3mm, the transition glaze raw materials include: feldspar 15%, quartz 18%, kaolin 12%, zinc oxide 6%, aluminum oxide 4%, borax 8%, and the balance is water, the specific gravity of the transition glaze is 1.25g / cm 3 , the glaze application amount is 80g / m 2 , the high-transparency wear-resistant glaze raw materials include: ordinary frit 20%, potassium feldspar 5%, calcined talc 10%, quartz 10%, borosilicate glass powder 15%, lanthanum oxide 0.8%, zinc oxide 4%, and the balance is water, the specific gravity of the high-transparency wear-resistant glaze is 1.35g / cm 3 , the glaze application amount is 280g / m 2 , the mineral composition of the frit is: potassium feldspar 35%, quartz 25%, barium carbonate 10%, raw talc 10%, coarse aluminum oxide 20%; the preparation method of the frit is: after mixing potassium feldspar, quartz, barium carbonate, raw talc and coarse aluminum oxide, heat at 800℃ for 20min, increase the temperature to 1300℃, keep for 2h, fully melt, and then quench to prepare;

[0061] Step 3, drying the green brick prepared in step 2 at 40℃ for 6h, heating to 300℃ at a heating rate of 5℃ / min, holding for 10min, heating to 700℃ at a heating rate of 10℃ / min, holding for 20min, maintaining the oxygen content in the kiln at 8%, heating to 1000℃ at a heating rate of 10℃ / min, holding for 20min, rough polishing with a resin-based elastic polishing block, polishing amount 0.05mm, diamond grinding disc, polishing amount 0.03mm, and finally polishing with a ceramic polishing liquid, polishing pressure 0.1MPa, polishing liquid flow rate 50mL / min, polishing amount 0.05mm, to obtain the high-gloss light-weight polished glazed tile.

[0062] Comparative Example 5

[0063] A method for preparing a high-gloss light-weight polished glazed tile, comprising the following steps:

[0064] Step 1, mixing composite high-alumina mud, expanded perlite, nano-zirconia and graphene according to a mass ratio of 60:22:1:0.5, ball milling to a D 50 value of 2μm to obtain a green body powder, wherein the composite high-alumina mud is composed of high-alumina mud and metakaolin according to a mass ratio of 8:1, and the A2O3 content in the high-alumina mud is 60wt%;

[0065] Step 2, pressing the green body powder to form a green body, and applying a base glaze, inkjet printing, a transition glaze and a high-transparency wear-resistant glaze on the green body to obtain a green brick, wherein the base glaze raw materials include: potassium feldspar 25%, nano-zirconia 1%, SnO2 22%, high-alumina mud 5%, and the balance is water, the specific gravity of the base glaze is 1.85g / cm 3 , and the glaze application amount is 120g / m 2 , the inkjet printing uses water-based permeable inkjet, the ink layer thickness is 10μm, after inkjet printing, drying at 80℃ for 10min, and the ink penetration depth after drying is 0.3mm, the transition glaze raw materials include: feldspar 15%, quartz 18%, high-alumina mud 12%, zinc oxide 6%, aluminum oxide 4%, borax 8%, and the balance is water, the specific gravity of the transition glaze is 1.25g / cm 3 , and the glaze application amount is 80g / m 2 , the high-transparency wear-resistant glaze raw materials include: frit 20%, potassium feldspar 5%, calcined talc 10%, quartz 10%, borosilicate glass powder 15%, lanthanum oxide 0.8%, zinc oxide 4%, and the balance is water, the specific gravity of the high-transparency wear-resistant glaze is 1.35g / cm 3 , and the glaze application amount is 280g / m 2The mineral composition of the clinker is: 35% potassium feldspar, 25% quartz, 10% barium carbonate, 10% raw talc, and 20% coarse aluminum oxide; the preparation method of the clinker is: after mixing potassium feldspar, quartz, barium carbonate, raw talc and coarse aluminum oxide, heating to 1300 DEG C, holding for 2h, fully melting, and then quenching to prepare;

[0066] Step 3, drying the green brick prepared in step 2 at 40 DEG C for 6h, heating to 300 DEG C at a heating rate of 5 DEG C / min, holding for 10min, heating to 700 DEG C at a heating rate of 10 DEG C / min, holding for 20min, maintaining the oxygen content in the kiln at 8%, heating to 1000 DEG C at a heating rate of 10 DEG C / min, holding for 20min, rough polishing with a resin-based elastic polishing block, a polishing amount of 0.05mm, a diamond grinding sheet, a polishing amount of 0.03mm, and finally polishing with a ceramic polishing liquid, a polishing pressure of 0.1MPa, a polishing liquid flow rate of 50mL / min, and a polishing amount of 0.05mm, to obtain the high-gloss light-weight polished glaze brick.

[0067] Performance test

[0068] The comprehensive performance of the high-gloss light-weight polished glaze bricks prepared in Examples 1-3 and Comparative Examples 1-5 is as follows:

[0069] Mohs hardness: the polished glaze brick sample is placed steadily on a hard support with the surface facing up. Different standard minerals with different Mohs values are used to scratch the surface of the sample from small to large. The lowest hardness value that can produce obvious scratches is used as the test result, and the lowest hardness value is used as the test result;

[0070] Wear resistance: tested according to the national standard GB / T3810.7-2016 "Ceramic tile test methods Part 7: determination of the surface wear resistance of glazed tiles";

[0071] Gloss: tested according to the national standard GB / T 13891-2008 "Building facing materials specular gloss determination method";

[0072] Bulk density: tested according to the industry standard JG / T 567-2019 "Lightweight high-strength ceramic plate for building";

[0073] The test results are shown in Table 1 below.

[0074] Table 1 Performance parameters of high-gloss light-weight polished glaze bricks prepared in Examples 1-3 and Comparative Examples 1-5

[0075] Test item MORRIS HARDNESS WEAR RESISTANCE RATING (4000 revolutions) Gloss (GU, 20°) Bulk density (g / cm 3 ) Example 1 6 4 84 1.79 Example 2 6 4 85 1.88 Example 3 6 4 88 1.76 Comparative Example 1 4 4 82 2.17 Comparative Example 2 5 4 81 2.05 Comparative Example 3 4 3 80 1.81 Comparative Example 4 4 4 75 1.78 Comparative Example 5 4 3 72 1.85

[0076] As shown in Table 1, the high-gloss light-weight glaze-finished tile prepared in the application not only has a high Mohs hardness, but also has a significant light-weight feature, so that the weight of the tile is greatly reduced, and the tile also has a high wear resistance grade and gloss, can effectively resist scratches and wear in daily use, and can ensure that the surface still maintains integrity and aesthetics after long-term use, has a wide application prospect and market value.

[0077] The specific embodiments are only an explanation of the application, and are not a limitation of the application, and those skilled in the art can make modifications to the embodiments without creative contribution according to the needs after reading the specification, but as long as the modifications are within the scope of the claims of the application, they are protected by the Patent Law.

Claims

1. A method for producing a high-gloss light-weight polished glaze tile, characterized by, It comprises the following steps: Step 1, mix composite high-aluminum mud, expanded perlite, nano zirconium oxide and graphene, ball mill to D 50 2-3 μm, get green body powder; Step 2, the green body powder is pressed to form a green body, and a base glaze, inkjet printing, transition glaze and high-transparency wear-resistant glaze are applied on the green body to obtain a brick body; Step 3, the brick body obtained in step 2 is dried and fired, and then is polished to obtain the high-gloss lightweight polished glaze brick; The mass ratio of the composite high-aluminum mud, expanded perlite, nano zirconium oxide and graphene in step 1 is 60-75:22-38:1-3:0.5-2; the composite high-aluminum mud is composed of high-aluminum mud and metakaolin with a mass ratio of 8-10:1-3; the A2O3 content in the high-aluminum mud is 60-80wt%; The high-transparency wear-resistant glaze raw material in step 2 comprises: frit 20-28%, potassium feldspar 5-12%, calcined talc 10-12%, quartz 10-12%, borosilicate glass powder 15-18%, lanthanum oxide 0.8-1.2%, zinc oxide 4-6%, and the high-transparency wear-resistant glaze has a specific gravity of 1.35-1.58 g / cm 3 , and the glazing amount is 280-350 g / m 2 . The mineral composition of the frit is: 25-35% of potassium feldspar, 20-25% of quartz, 10-18% of barium carbonate, 8-15% of raw talc and 15-20% of coarse aluminum oxide; the preparation method of the frit is: after mixing potassium feldspar, quartz, barium carbonate, raw talc and coarse aluminum oxide, heating at 800-1000℃ for 20-30min, increasing the temperature to 1300-1500℃ and keeping for 2-4h, and then quenching after full melting.

2. The method of claim 1, wherein the high-gloss, light-weight, enamel glazed tile is prepared by the steps of: The underglaze raw material in step 2 comprises: potassium feldspar 25-35%, nano zirconium oxide 1-3%, SnO2 2-4%, kaolin 5-10%, and the underglaze specific gravity is 1.85-1.95 g / cm 3 , and the glazing amount is 120-180 g / m 2 .

3. The method of claim 1, wherein the high-gloss, light-weight, enamel glazed tile is prepared by the steps of: In step 2, any one or combination of oil-based inkjet, water-based inkjet, roller printing and sunken inkjet is used for inkjet printing; the ink layer thickness is 10-30μm; after inkjet printing, drying at 80-120℃ for 10-15min; and after drying, the ink penetration depth is ≥0.3mm.

4. The method of claim 1, wherein the high-gloss, light-weight, polished glaze tile is prepared by the steps of: The transition glaze raw material in step 2 comprises: feldspar 15-18%, quartz 18-22%, kaolin 12-18%, zinc oxide 6-9%, aluminum oxide 4-7%, borax 8-11%, and the specific gravity of the transition glaze is 1.25-1.52 g / cm 3 , and the glazing amount is 80-150 g / m 2 .

5. The method of claim 1, wherein the high-gloss, light-weight, enamel glazed tile is prepared by the steps of: In step 3, the firing adopts gradient temperature control: increasing the temperature to 300-600℃ at a heating rate of 5-8℃ / min, keeping for 10-15min, increasing the temperature to 700-1000℃ at a heating rate of 10-12℃ / min, keeping for 20-25min while maintaining the oxygen content in the kiln at 8-12%, and increasing the temperature to 1000-1150℃ at a heating rate of 10-12℃ / min, keeping for 20-30min.

6. The method of producing high-gloss, light-weight polished glaze tiles according to claim 1, characterized in that, In step 3, the composite polishing process is: first, rough polishing with a resin-based elastic abrasive block, the polishing amount is 0.05-0.1mm; then, polishing with a diamond abrasive sheet, the polishing amount is 0.03-0.05mm; and finally, polishing with a ceramic polishing liquid, the polishing pressure is 0.1-0.2MPa, the polishing liquid flow rate is 50-80mL / min, and the polishing amount is 0.05-0.1mm.

7. A high-gloss lightweight polished glaze brick prepared by the preparation method of any one of claims 1-6.