Repair process for ceramic glaze defects

Abstract

The invention discloses a ceramic glaze defect repairing process which comprises the following steps: S1, defect cleaning: firstly, thoroughly removing dirt, impurities and the like at a ceramic glaze defect by using a special cleaning agent to ensure that a repaired surface is clean and tidy, and carrying out filling and grinding pretreatment operation on relatively large defects such as cracks or damages; s2, preparing a repairing material: selecting a proper repairing material according to the characteristics of color, texture and the like of the ceramic product; the micro-jet printing technology serves as a printing mode based on the ink jet technology, and copying and output of high-quality images can be achieved by accurately controlling jet of tiny ink droplets. The technology can ensure that the repaired ceramic glaze surface is well restored in color, details and texture, so that the effect that the repaired ceramic glaze surface is highly consistent with the original glaze surface is achieved. And local laser sintering can be used for finely repairing the glaze surface on a microscopic level, so that the repairing precision and quality are further enhanced.

Description

Technical Field

[0001] The invention relates to the technical field of repairing ceramic glaze defects, in particular to a process for repairing ceramic glaze defects. Background Art

[0002] Today, ceramic sanitary ware (such as wash basins, bathtubs and toilets) has entered thousands of households. With the continuous improvement of the technology in the ceramic sanitary ware industry and the increasing demand for ceramic sanitary ware from consumers, ceramic sanitary ware has gradually developed towards complex shapes and larger sizes.

[0003] According to the patent titled "A Repair Process for Ceramic Glaze Defects" (patent publication number: CN119390480A, patent publication date: 2025-02-07), the process includes the following steps: A. Grinding the defective area of ​​the ceramic into a U-shaped groove and wetting the U-shaped groove to obtain a pretreated ceramic; B. Filling the U-shaped groove of the pretreated ceramic with a repair base material and compacting it to obtain a repair base layer; C. Drying and grinding the repair base layer in sequence to make the surface of the repair base layer flush with the surface of the pretreated ceramic; D. Filling the repair glaze on the surface of the repair base layer and compacting it to form a repair surface layer; E. Placing the pretreated ceramic with the repair surface layer in a shuttle kiln to complete the repair. The proposed repair process for ceramic glaze defects optimizes the formula of the repair base material and the repair process, which helps reduce firing shrinkage and cracking potential and improves repair strength. While ensuring the repair effect, it not only increases the range of repairable defects, but also makes the repaired ceramic glaze defects smooth and flat, ensuring aesthetics.

[0004] Based on the above-mentioned existing technologies, the current existing ceramic glaze defect repair process still has the following problems. Traditional repair processes are mostly manual repairs, which are difficult to accurately fill micron-level defects. The repaired ceramic glaze surface is difficult to achieve a good restoration in color, detail and texture. For this reason, the present invention provides a ceramic glaze defect repair process. Summary of the Invention

[0005] In response to the shortcomings of the existing technology, the present invention provides a repair process for ceramic glaze defects, which solves the problem that traditional repair processes are mostly manual repairs, it is difficult to accurately fill micron-level defects, and it is difficult to achieve a good restoration of the color, details and texture of the repaired ceramic glaze.

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions: A process for repairing ceramic glaze defects, specifically comprising the following steps:

[0007] S1. Defect cleaning: First, use a special cleaning agent to thoroughly remove dirt, impurities, etc. from the defects of the ceramic glaze to ensure that the repair surface is clean and tidy. For larger defects such as cracks or damage, fill and smooth the pre-treatment operations;

[0008] S2. Preparation of repair materials: Select appropriate repair materials based on the color, texture and other characteristics of the ceramic product;

[0009] S3, Repair Operation: The repair material is loaded into the piezoelectric droplet ejection system, and a layered printing path is generated based on the 3D scanning data to accurately fill the defect area;

[0010] S4, curing treatment: The depth, width and morphology data of the defects are obtained through a laser scanner, and the fiber laser is used to perform laser scanning and sintering immediately after each layer is printed in a piezoelectric droplet injection system to solidify the material;

[0011] S5. Grinding and polishing: After curing, use special grinding and polishing tools to grind and polish the repaired area to restore the gloss and flatness of the ceramic glaze;

[0012] S6. Quality inspection: Carry out quality inspection on the repaired ceramic products to ensure that there is no obvious color difference or unevenness between the repaired area and the surrounding glaze surface.

[0013] Preferably, the grinding operation in S1 can be performed using a steel brush and sandpaper to remove protrusions and uneven parts generated during the filling process, and the sandpaper is 1000 fine sandpaper.

[0014] Preferably, the repair material in S2 is a nanocomposite suspension, which is obtained by ball milling, mixing, screening and vacuum degassing.

[0015] Preferably, the nozzle diameter of the piezoelectric droplet ejection system in S3 is 20-50 μm, the ejection frequency is 1-10 kHz, the printing accuracy is ±10 μm, and the glaze layer after micro-spray printing is pre-dried to remove the solvent.

[0016] Preferably, the fiber laser used in S4 has a wavelength of 1064 nm, a power range of 50-200 W, a spot diameter of 50-200 μm, which matches the defect size, and the spot diameter is less than 1.5 times the defect width.

[0017] Preferably, the fiber laser in S4 is equipped with a dynamic focusing lens group and a galvanometer scanning system with a scanning speed of 100-1000 mm / s to ensure the focusing stability of the laser beam on the curved surface.

[0018] Preferably, the fiber laser used in S4 is sintered immediately after printing each layer, and a serpentine path or a concentric circle path is used to make the spot overlap rate 20%-30%.

[0019] Preferably, in S6, X-ray imaging is used to detect whether there is obvious color difference or unevenness between the repaired area and the surrounding glaze surface.

[0020] Beneficial effects

[0021] The present invention provides a repair process for ceramic glaze defects. Compared with the prior art, it has the following advantages:

[0022] Beneficial effects:

[0023] 1. This ceramic glaze defect repair process uses micro-jet printing technology, a printing method based on inkjet technology. By precisely controlling the ejection of tiny ink droplets, it can achieve high-quality image reproduction and output. This technology ensures that the repaired ceramic glaze surface is perfectly restored in color, detail, and texture, achieving a highly consistent effect with the original glaze. Localized laser sintering can perform detailed repairs on the glaze surface at a microscopic level, further enhancing the precision and quality of the repair.

[0024] 2. This ceramic glaze defect repair process utilizes a solution made from specialized materials used in microjet printing technology (typically high-quality pigment inks), which exhibits excellent lightfastness, water resistance, and oxidation resistance. This means the repaired ceramic glaze maintains vibrant colors and clear images for extended periods, resisting fading or damage. Localized laser sintering, through a high-temperature melting and rapid cooling process, densifies and stabilizes the material of the repaired area, thereby improving its durability and wear resistance.

[0025] 3. For this ceramic glaze defect repair process, microjet printing technology offers a wide range of material options and the ability to provide customized services. This means that appropriate materials and patterns can be selected based on the specific defects and repair requirements. Furthermore, localized laser sintering technology offers a high degree of flexibility, enabling targeted repair of defects of varying shapes and sizes. This ability to customize and flexibly adapt the repair process to diverse ceramic glaze defect repair needs. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a process flow chart of the present invention; DETAILED DESCRIPTION

[0027] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0028] See also Figure 1 The present invention provides a technical solution: a process for repairing ceramic glaze defects, which specifically includes the following steps:

[0029] S1. Defect cleaning: First, use a special cleaning agent to thoroughly remove dirt, impurities, etc. from the defects of the ceramic glaze to ensure that the repair surface is clean and tidy. For larger defects such as cracks or damage, fill and smooth the pre-treatment operations;

[0030] S2. Preparation of repair materials: Select appropriate repair materials based on the color, texture and other characteristics of the ceramic product;

[0031] S3, Repair Operation: The repair material is loaded into the piezoelectric droplet ejection system, and a layered printing path is generated based on the 3D scanning data to accurately fill the defect area;

[0032] S4, curing treatment: The depth, width and morphology data of the defects are obtained through a laser scanner, and the fiber laser is used to perform laser scanning and sintering immediately after each layer is printed in a piezoelectric droplet injection system to solidify the material;

[0033] S5. Grinding and polishing: After curing, use special grinding and polishing tools to grind and polish the repaired area to restore the gloss and flatness of the ceramic glaze;

[0034] S6. Quality inspection: Carry out quality inspection on the repaired ceramic products to ensure that there is no obvious color difference or unevenness between the repaired area and the surrounding glaze surface.

[0035] In the present invention, the grinding operation in S1 can be performed using a steel brush and sandpaper to remove protrusions and uneven parts generated during the filling process, and the sandpaper is 1000 fine sandpaper.

[0036] In the present invention, the repair material in S2 is a nanocomposite suspension, which is obtained by ball milling, mixing, screening and vacuum degassing.

[0037] The nanoparticle agglomerates were broken up by the mechanical shearing and impact action of the ball mill (rotation speed 200-400 rpm, time 2-4 h), and the particle size distribution D50 was reduced from micron level to less than 200 nm, ensuring the uniformity of the suspension.

[0038] Nanocomposite glaze formula:

[0039] Basic components: nano-Al2O3 (20-40wt%), SiO2 sol (10-25wt%), organic binder (PVP or PEG, 5-10wt%);

[0040] Rheology adjustment: add 0.1-0.5 wt% dispersant (such as ammonium polyacrylate) and control the viscosity at 100-300 cP (25°C).

[0041] In the present invention, the nozzle diameter of the piezoelectric droplet ejection system in S3 is 20-50 μm, the ejection frequency is 1-10 kHz, the printing accuracy is ±10 μm, and the glaze layer after micro-spray printing is pre-dried to remove the solvent.

[0042] The tiny nozzles can generate droplets with a diameter of 30-100μm, accurately matching micron-level defects (such as 0.1mm cracks or pinholes), achieving ±10μm positioning accuracy, and avoiding over-coverage of traditional spraying.

[0043] High-frequency jet single-layer printing speed reaches 10-50mm 2 / s, the filling time of a single point defect (0.5mm×0.5mm) is less than 30 seconds, which is 5-10 times more efficient than traditional manual repair.

[0044] In the present invention, the fiber laser used in S4 has a wavelength of 1064 nm, a power range of 50-200 W, a spot diameter of 50-200 μm, which matches the defect size, and the spot diameter is less than 1.5 times the defect width.

[0045] The absorption rate of 1064nm wavelength for ceramic glaze (containing SiO2, Al2O3 and other components) is greater than 60% (compared to the absorption rate of CO2 laser 10.6μm wavelength, it is more than 3 times higher), reducing energy reflection loss and improving thermal efficiency.

[0046] The spot diameter is less than 1.5 times the defect width (for example, a 0.2mm wide crack matches a 0.3mm spot), ensuring that the laser energy completely covers the defect area and avoids substrate damage.

[0047] In the present invention, the fiber laser in S4 is equipped with a dynamic focusing lens group and a galvanometer scanning system with a scanning speed of 100-1000 mm / s to ensure the focusing stability of the laser beam on the curved surface.

[0048] The dynamic focusing lens group compensates for changes in surface height in real time through Z-axis adjustment, ensuring that the laser focus is always on the workpiece surface and avoiding energy attenuation caused by defocus. For non-planar or special-shaped ceramics (such as reliefs and grooves), dynamic focusing can match the surface topography (through synchronous feedback of 3D scanning data) to achieve uniform sintering across the entire area, avoiding the local overburning or unmelting problems of traditional fixed-focus processes.

[0049] The galvanometer scanning speed reaches 100-1000mm / s, supporting the rapid execution of complex paths (such as spirals, grids, and gradient fills). The single-point repair time is shortened to less than 2 minutes, and the repair efficiency is increased by 5-10 times.

[0050] In the present invention, the fiber laser used in S4 is sintered immediately after printing each layer, and a serpentine path or a concentric circle path is used to ensure that the spot overlap rate is 20%-30%.

[0051] Each printed layer (5-20 μm thick) is sintered immediately to ensure that the molten glaze fully fills the micropores in the liquid state, and the porosity of the single layer is less than 1%.

[0052] When multiple layers are stacked, they are densified layer by layer to form a gradient structure (density changes from 90% at the bottom layer to more than 98% at the surface layer), reducing shrinkage stress concentration.

[0053] By alternating the scanning direction (the interval between adjacent paths is 80% of the spot diameter), the temperature gradient is reduced and the residual stress is less than 50 MPa.

[0054] In the present invention, in S6, X-ray imaging is used to detect whether there is obvious color difference or unevenness between the repaired area and the surrounding glaze surface.

[0055] As a non-destructive testing technique, X-ray imaging can be used to inspect the repaired area without damaging the surrounding glaze. This means that no physical damage is caused to the repaired area during the inspection process, thus preserving the integrity of the repaired area and the glaze.

[0056] X-ray imaging technology is highly precise and can clearly show subtle differences between the repaired area and the surrounding glaze. This high-precision detection capability allows inspectors to accurately determine whether there are color differences, unevenness, or unevenness in the repaired area, thereby improving the accuracy and reliability of the inspection.

[0057] Meanwhile, the contents not described in detail in this specification belong to the prior art known to those skilled in the art.

[0058] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0059] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A process for repairing ceramic glaze defects, characterized by: The specific steps include: S1. Defect cleaning: First, use a special cleaning agent to thoroughly remove dirt, impurities, etc. from the defects of the ceramic glaze to ensure that the repair surface is clean and tidy. For larger defects such as cracks or damage, fill and smooth the pre-treatment operations; S2. Preparation of repair materials: Select appropriate repair materials based on the color, texture and other characteristics of the ceramic product; S3, Repair Operation: The repair material is loaded into the piezoelectric droplet ejection system, and a layered printing path is generated based on the 3D scanning data to accurately fill the defect area; S4, curing treatment: The depth, width and morphology data of the defects are obtained through a laser scanner, and the fiber laser is used to perform laser scanning and sintering immediately after each layer is printed in a piezoelectric droplet injection system to solidify the material; S5. Grinding and polishing: After curing, use special grinding and polishing tools to grind and polish the repaired area to restore the gloss and flatness of the ceramic glaze; S6. Quality inspection: Carry out quality inspection on the repaired ceramic products to ensure that there is no obvious color difference or unevenness between the repaired area and the surrounding glaze surface.

2. The process for repairing ceramic glaze defects according to claim 1, characterized in that: The grinding operation in S1 can be performed using a steel brush and sandpaper to remove protrusions and uneven parts generated during the filling process, and the sandpaper is 1000 fine sandpaper.

3. The process for repairing ceramic glaze defects according to claim 1, characterized in that: The repair material in S2 is a nanocomposite suspension, which is obtained by ball milling, sieving and vacuum degassing.

4. The process for repairing ceramic glaze defects according to claim 1, characterized in that: The nozzle diameter of the piezoelectric droplet ejection system in S3 is 20-50 μm, and the ejection frequency is 1-10 kHz. The printing accuracy is ±10 μm, and the glaze layer after micro-spray printing is pre-dried to remove the solvent.

5. The process for repairing ceramic glaze defects according to claim 1, characterized in that: The fiber laser used in S4 has a wavelength of 1064nm, a power range of 50-200W, and a spot diameter of 50-200μm, which matches the defect size, and the spot diameter is less than 1.5 times the defect width.

6. The process for repairing ceramic glaze defects according to claim 1, characterized in that: The fiber laser in the S4 is equipped with a dynamic focusing lens group and a galvanometer scanning system with a scanning speed of 100-1000 mm / s to ensure the focusing stability of the laser beam on the curved surface.

7. The process for repairing ceramic glaze defects according to claim 1, characterized in that: The fiber laser used in the S4 is sintered immediately after printing each layer, and a serpentine path or a concentric circle path is used to ensure that the spot overlap rate is 20%-30%.

8. The process for repairing ceramic glaze defects according to claim 1, characterized in that: In the step S6, X-ray imaging is used to detect whether there is obvious color difference or unevenness between the repaired area and the surrounding glaze surface.

Images