Ceramic tile with digital concave-convex effect and preparation process

Abstract

The invention relates to architectural ceramics, and discloses a ceramic tile with a digital concave-convex effect and a preparation method, the method comprises the following steps: S1, pressing powder into a green brick to form a green body layer; s2, sequentially spraying cover glaze on the green body layer, carrying out ink-jet printing on digital mold ink, spraying the cover glaze, and drying to form a digital mold effect layer; s3, performing ink-jet printing of color patterns on the digital mold effect layer to form a pattern layer; s4, performing silk-screen printing of color-enhanced glaze on the pattern layer to form a color-enhanced glaze layer; s5, performing ink-jet printing of positioning glue on the color-enhanced glaze layer, and applying positioning dry particles to form a positioning dry particle layer; s6, spraying dry particle protective glaze on the positioning dry particle layer to form a protective glaze layer; and S7, the ceramic tile is fed into a kiln to be sintered, the sintered semi-finished ceramic tile is brushed and polished, and the ceramic tile with the digital concave-convex effect is obtained. The ceramic tile prepared by the method has rich, natural and vivid concave-convex textures, the reduction degree of materials with bright colors is high, and the ceramic tile has high wear resistance and high antifouling property.

Description

Technical Field

[0001] The present invention relates to the field of building ceramics, and in particular to a ceramic tile with digital concave-convex effect and a preparation process thereof. Background Art

[0002] Marble tiles, a groundbreaking innovation in the ceramics industry, offer superior hardness, stain resistance, and wear resistance compared to natural stone. Combining aesthetic value with practical functionality, they effectively replace non-renewable natural stone resources. As living standards and aesthetic tastes improve, the aesthetic demands of the new generation of consumers for marble tiles are also evolving.

[0003] In recent years, tile surface processing has shown a trend of increasing complexity, diversification, and refinement. To meet market demand, advanced equipment and technologies have been introduced both domestically and internationally. Digital mold technology is particularly prominent. Its core principle is to achieve the concave and convex texture effects on the tile surface by using the principle of mutual repulsion between oil-based ink (specifically formulated) and water-based glaze slurry.

[0004] Despite the continuous advancements in digital mold technology within the ceramic tile industry, its practical application still faces limitations, hindering its ability to fully meet market demand for diverse and refined products. For one thing, digital mold technology offers a relatively limited product range and a limited range of process dimensions. Furthermore, its detailed texture designs often exhibit rigid, thin lines (a single, finely etched ink), lacking refined transitions and failing to accurately reproduce the natural, detailed textures of the stone. Furthermore, some digital mold products suffer from the collapse of the dry grain effect, resulting in an unnatural transition between convex and concave surfaces, which compromises the overall texture and aesthetics of the product. These issues demonstrate that while digital mold technology can achieve certain textures and effects, there remains a balance between naturally transitioning convex and concave textures and the refinement of detailed textures. Summary of the Invention

[0005] The main purpose of the present invention is to propose a method for preparing ceramic tiles with digital concave-convex effects, which can produce concave-convex texture effects with higher precision and natural transition, while ensuring that the ceramic tiles have good physical properties such as high wear resistance and high anti-fouling properties.

[0006] To achieve the above object, the present invention provides a method for preparing a ceramic tile with a digital concave-convex effect, comprising the following steps: S1, pressing the powder into a brick to form a body layer; S2, sequentially pouring a first glaze, inkjet printing a digital mold ink, and spraying a second glaze on the green body layer, and forming a digital mold effect layer after drying; S3, inkjet printing a color pattern on the digital mold effect layer to form a pattern layer; S4, screen printing a color-enhancing glaze on the pattern layer to form a color-enhancing glaze layer; S5, inkjet printing positioning glue on the color-enhancing glaze layer, applying positioning dry particles, and forming a positioning dry particle layer; S6, spraying dry particle protective glaze on the positioned dry particle layer to form a protective glaze layer; S7, sending the semi-finished ceramic tile into a kiln for firing, and brushing and polishing the fired semi-finished ceramic tile to obtain a ceramic tile with a digital concave-convex effect.

[0007] Preferably, in step S2, the chemical composition of the first glaze and the second glaze, calculated in percentage by mass of oxides, includes: SiO2: 52-57%, Al2O3: 22-26%, Fe2O3: 0.1-0.5%, CaO: 1-5%, MgO: 0.1-0.4%, K2O: 1-5%, Na2O: 1-5%, P2O5: 0.1-0.3%, BaO: 0.1-0.5%, ZrO2: 7-12%, and ignition loss 1-5%; In step S5, the chemical composition of the dry particles, in terms of percentage by mass of oxides, includes: SiO2: 47-50%, Al2O3: 15-20%, Fe2O3: 0.05-0.2%, CaO: 5-10%, MgO: 1-5%, K2O: 2-7%, Na2O: 1-4%, BaO: 7-10%, ZnO: 3-7%, SrO: 1-5%, and loss on ignition 0.1-0.5%; In step S6, the chemical composition of the dry particle protective glaze, calculated in percentage by mass of oxides, includes: SiO2: 50-55%, Al2O3: 15-20%, CaO: 5-10%, MgO: 1-4%, K2O: 2-5%, Na2O: 1-5%, BaO: 5-10%, ZnO: 2-7%, SrO: 2-6%, and ignition loss of 0.05-0.3%.

[0008] The present invention achieves a high degree of integration of digital mold and material design through the selection of surface glaze, dry particles and dry particle protective glaze formula, and the control of process parameters, thereby obtaining a natural, varied, complex and transitional high-precision pattern texture, creating rich, natural and vivid concave and convex changes.

[0009] Preferably, in step S2, the specific gravity of the first glaze is 1.80-1.90 g / mL, the specific gravity of the second glaze is 1.52±0.01 g / mL, and the spraying amount of the second glaze is 85±1 g / (300*600 pans), which can form a clear and naturally transitioned concave texture effect.

[0010] Preferably, in step S2, the drying temperatures are set to 130-135°C, 160-165°C, and 205-210°C, respectively.

[0011] Preferably, in step S4, the color-enhancing glaze layer is formed by three-layer screen printing; the first layer of screen printing materials includes, by weight, 100 parts of basic glaze and 4 parts of bright red material; the second layer of screen printing materials includes, by weight, 100 parts of basic glaze, 0.4 parts of peach color material, 0.3 parts of dark brown material, and 0.1 parts of cobalt black material; the third layer of screen printing materials includes, by weight, 100 parts of basic glaze, 4 parts of iron red material, and 0.12 parts of cobalt black material; The chemical composition of the basic glaze, calculated in percentage by mass of oxides, includes: SiO2: 45-50%, Al2O3: 17-22%, Fe2O3: 0.1-0.4%, CaO: 10-15%, MgO: 1-5%, K2O: 0.5-1.0%, Na2O: 1-5%, BaO: 1-4%, ZnO: 2-7% and ignition loss of 5-10%.

[0012] Preferably, in step S5, the amount of the dry particles used is 70±1 g / (300*600 plates).

[0013] Preferably, in step S6, the glazing amount of the dry particle protective glaze is 31±1 g / (300*600 pans).

[0014] Preferably, in step S7, the firing temperature is 1200-1230° C., and the firing period is 63-67 minutes.

[0015] Preferably, the brushing and polishing parameters are 10 sets of 1000-mesh abrasive brushes, 6 sets of 80-mesh hard sponge brushes, and 6 sets of 120-mesh matte grinding blocks. By selecting appropriate brushing and polishing parameters, the tile surface has high wear resistance and high stain resistance, while taking into account the touch and light perception, and the overall coordination is optimal.

[0016] In another aspect, the present invention also discloses a ceramic tile with a digital concave-convex effect, produced using any of the aforementioned methods. The tile has a smooth and delicate texture, rich and precise concave-convex textures, natural and vivid transitions, vibrant colors, and high fidelity. Furthermore, the tile exhibits excellent physical properties, including high wear resistance and stain resistance. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following briefly introduces the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are only some embodiments of the present application. For ordinary technicians in this field, other relevant drawings can be obtained based on these drawings without paying any creative work.

[0018] Figure 1 The actual effect of the tile in Example 4 Figure 1 ; Figure 2 The actual effect of the tile in Example 4 Figure 2 ; Figure 3 The actual effect of the tile in Example 4 Figure 3 ; Figure 4 This is a micrograph of the detailed texture of the tile of Example 4; Figure 5 These are the micro texture undulation effects of the ceramic tile of Example 4 under different lighting conditions.

[0019] The realization of the objectives, functional features and advantages of this application will be further explained in conjunction with embodiments and with reference to the accompanying drawings. DETAILED DESCRIPTION

[0020] The technical solutions in the embodiments of the present invention will be described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments in the present invention, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention. It should be noted that the embodiments in this application and the features in the embodiments can be combined with each other unless there is a conflict. At the same time, the raw materials mentioned below that are not described in detail are all commercially available products; the process steps or preparation methods not mentioned in detail are all process steps or preparation methods known to those skilled in the art.

[0021] The present invention discloses a method for preparing a ceramic tile with a digital concave-convex effect, comprising the following steps: S1, pressing the powder into a brick to form a body layer; S2, sequentially pouring a first glaze, inkjet printing a digital mold ink, and spraying a second glaze on the green body layer, and forming a digital mold effect layer after drying; S3, inkjet printing a color pattern on the digital mold effect layer to form a pattern layer; S4, screen printing a color-enhancing glaze on the pattern layer to form a color-enhancing glaze layer; S5, inkjet printing positioning glue on the color-enhancing glaze layer, applying positioning dry particles, and forming a positioning dry particle layer; S6, spraying dry particle protective glaze on the positioned dry particle layer to form a protective glaze layer; S7. The tiles are placed in a kiln for firing at a temperature of 1200-1230°C for a period of 63-67 minutes. The fired semi-finished tiles are then polished using ten sets of 1000-mesh abrasive brushes, six sets of 80-mesh hard sponge brushes, and six sets of 120-mesh matte grinding blocks. The result is a tile with a digital embossed effect.

[0022] In step S2, the specific gravity of the first glaze is 1.80-1.90 g / mL, the specific gravity of the second glaze is 1.52±0.01 g / mL, and the spraying amount of the second glaze is 85±1 g / (300*600 pans). Preferably, the chemical composition of the first glaze and the second glaze, in terms of mass percentage of oxides, includes: SiO2: 52-57%, Al2O3: 22-26%, Fe2O3: 0.1-0.5%, CaO: 1-5%, MgO: 0.1-0.4%, K2O: 1-5%, Na2O: 1-5%, P2O5: 0.1-0.3%, BaO: 0.1-0.5%, ZrO2: 7-12%, and ignition loss of 1-5%. The above glaze formula can be used in both the pouring glaze and the spraying glaze processes to achieve the best texture effect, and the specific gravity of the glaze is adjusted by adding water.

[0023] In step S2, the digital mold ink uses CZN00588 deep ink and CZN00597 light transition ink produced by Taolixi (Suzhou) Ceramic Glaze Color Co., Ltd.

[0024] In step S2, the drying temperatures are set to 130-135°C, 160-165°C, and 205-210°C, respectively.

[0025] The glaze formula described in this invention offers improved water retention and fluidity, maintaining moisture during the glaze peeling process and creating a clearer, more natural texture. Furthermore, precise control of the glaze application and the gradient setting of the drying temperature prevent excessive moisture in the body, achieving an ideal peeling effect.

[0026] In step S4, the color-enhancing glaze layer is formed using three layers of screen printing; the screen mesh size is 180. The first layer of screen printing materials, by weight, includes: 100 parts of basic glaze and 4 parts of bright red pigment; the second layer of screen printing materials, by weight, includes: 100 parts of basic glaze, 0.4 parts of peach pigment, 0.3 parts of dark brown pigment, and 0.1 parts of cobalt black pigment; the third layer of screen printing materials, by weight, includes: 100 parts of basic glaze, 4 parts of iron red pigment, and 0.12 parts of cobalt black pigment. The chemical composition of the basic glaze, calculated in percentage by mass of oxides, includes: SiO2: 45~50%, Al2O3: 17~22%, Fe2O3: 0.1~0.4%, CaO: 10~15%, MgO: 1~5%, K2O: 0.5~1.0%, Na2O: 1~5%, BaO: 1~4%, ZnO: 2~7% and ignition loss 5~10%.

[0027] This invention uses screen printing to optimize the red and gray colors of the pattern layer by mixing different colorants with a base glaze. The first layer of screen-enhanced glaze achieves optimal color rendering for bright red; the second layer of screen-enhanced glaze achieves optimal color rendering for gray; and the third layer of screen-enhanced glaze achieves optimal color rendering for purple. By stacking these three layers of screen, the texture details of the pattern layer are restored to over 85%, resulting in a natural, lifelike, vibrant, and richly colored surface with a rich, rich feel.

[0028] In step S5, the chemical composition of the dry particles, in terms of oxide percentage by mass, includes: SiO2: 47-50%, Al2O3: 15-20%, Fe2O3: 0.05-0.2%, CaO: 5-10%, MgO: 1-5%, K2O: 2-7%, Na2O: 1-4%, BaO: 7-10%, ZnO: 3-7%, SrO: 1-5%, and loss on ignition 0.1-0.5%. The amount of dry particles used is 70±1 g / (300*600 pans).

[0029] In step S6, the chemical composition of the dry granular protective glaze, calculated by mass percentage of oxides, includes: SiO2: 50-55%, Al2O3: 15-20%, CaO: 5-10%, MgO: 1-4%, K2O: 2-5%, Na2O: 1-5%, BaO: 5-10%, ZnO: 2-7%, SrO: 2-6%, and an ignition loss of 0.05-0.3%. The glaze amount of the dry granular protective glaze is 31±1 g / (300*600 pans).

[0030] The present invention utilizes a combination of the aforementioned dry particles and a dry particle protective glaze to create a slightly convex effect in localized areas of the tile surface, enhancing both the visual layering and the tactile three-dimensionality. Furthermore, by adjusting the composition of the dry particles and the dry particle protective glaze, the protective glaze achieves an appropriate melting rate, providing a smooth exhaust path for gases generated during the melting of the dry particles. This reduces the formation of pores and pinholes on the tile surface and improves the tile's anti-fouling properties.

[0031] The following examples are further listed to illustrate the present invention in detail. It should also be understood that the following examples are only used to further illustrate the present invention and should not be construed as limiting the scope of protection of the present invention. Some non-essential improvements and adjustments made by those skilled in the art based on the above content of the present invention all fall within the scope of protection of the present invention. The specific process parameters of the following examples are also only examples within a suitable range, that is, those skilled in the art can make selections within a suitable range through the description herein, and are not intended to be limited to the specific numerical values ​​of the examples below. For those in the examples where specific conditions are not specified, proceed according to conventional conditions or the conditions recommended by the manufacturer.

[0032] It should be noted that the green body layer in the preparation method of the present invention can adopt a conventional green body formulation in the art. For example, the green body raw materials in the following examples and comparative examples include, by weight, 16 parts potassium feldspar, 19 parts sodium feldspar, 21 parts kaolin, 16 parts wollastonite, 8 parts calcined talc, 10 parts zinc oxide, 3 parts barium oxide, and 7 parts quartz. The digital mold inks used in the following examples and comparative examples are CZN00588 deep ink and CZN00597 light transition ink from Taolixi (Suzhou) Ceramic Glaze Co., Ltd.

[0033] Example 1 A method for preparing a ceramic tile with a digital concave-convex effect comprises the following steps: S1, pressing the powder into a brick to form a body layer; S2. On the green body layer, a first glaze is sequentially applied, digital mold ink is inkjet printed, and a second glaze is sprayed. The drying temperatures are sequentially set to 130° C., 160° C., and 210° C., and a digital mold effect layer is formed after drying. The chemical composition of the first glaze, in terms of the mass percentage of oxides, includes: SiO2: 50.93%, Al2O3: 21.01%, Fe2O3: 0.20%, CaO: 8.60%, MgO: 3.67%, K2O: 1.69%, Na2O: 1.97%, BaO: 1.96%, ZnO: 0.96%, ZrO 2:0.38% and ignition loss 8.44%, the first glaze specific gravity is 1.81g / mL; the chemical composition of the second glaze includes: SiO2:54.11%, Al2O3:24.06%, Fe2O3:0.25%, CaO:2.90%, MgO:0.19%, K2O:3.59%, Na2O:2.67%, P2O5:0.12%, BaO:0.26%, ZrO2:9.29% and ignition loss 2.45%; the second glaze specific gravity is 1.52g / mL, and the second glaze spraying amount is 85g / (300*600 plates); S3, inkjet printing a color pattern on the digital mold effect layer to form a pattern layer; S4. Screen-printing a color-enhancing glaze on the pattern layer to form a color-enhancing glaze layer; this is done using three layers of screen printing; the mesh size of the screen is 180. The first layer of screen-printing materials comprises, by weight, 100 parts of a basic glaze and 4 parts of a bright red pigment; the second layer of screen-printing materials comprises, by weight, 100 parts of a basic glaze, 0.4 parts of a peach pigment, 0.3 parts of a dark brown pigment, and 0.1 parts of a cobalt black pigment; and the third layer of screen-printing materials comprises, by weight, 100 parts of a basic glaze, 4 parts of an iron red pigment, and 0.12 parts of a cobalt black pigment. The chemical composition of the basic glaze, in terms of the mass percentage of oxides, includes: SiO2: 48.43%, Al2O3: 19.76%, Fe2O3: 0.19%, CaO: 11.57%, MgO: 2.99%, K2O: 0.65%, Na2O: 2.64%, BaO: 1.67%, ZnO: 4.52% and ignition loss 7.44%; S5. Inkjet printing positioning glue on the color-enhancing glaze layer and applying positioning dry particles to form a positioning dry particle layer; wherein the chemical composition of the dry particles, in terms of mass percentage of oxides, comprises: SiO2: 49.42%, Al2O3: 18.10%, Fe2O3: 0.10%, CaO: 7.44%, MgO: 1.82%, K2O: 4.39%, Na2O: 1.39%, BaO: 8.01%, ZnO: 5.64%, SrO: 3.31%, and loss on ignition: 0.27%; the amount of dry particles used is 70 g / (300*600 trays); S6. Spray a dry granular protective glaze onto the positioned dry granular layer to form a protective glaze layer. The chemical composition of the dry granular protective glaze, in percentage by mass of oxides, comprises: SiO2: 52.90%, Al2O3: 17.41%, CaO: 6.66%, MgO: 1.25%, K2O: 3.87%, Na2O: 2.40%, BaO: 6.78%, ZnO: 4.40%, SrO: 4.08%, and ignition loss: 0.10%. The dry granular protective glaze is applied in an amount of 31 g / (300 x 600 pans).

[0034] S7: Place the tile in a kiln for firing at 1227°C for a period of 63.66 minutes. The fired semi-finished tile is then polished using ten sets of 1000-mesh abrasive brushes, six sets of 80-mesh hard sponge brushes, and six sets of 120-mesh matte abrasive blocks. The result is a tile with a digital embossed effect.

[0035] Example 2 A method for preparing a ceramic tile with a digital concave-convex effect comprises the following steps: S1, pressing the powder into a brick to form a body layer; S2. On the green body layer, a first glaze, inkjet-printed digital mold ink, and a second glaze are sequentially applied. The drying temperatures are sequentially set to 130° C., 160° C., and 210° C. to form a digital mold effect layer after drying. The chemical compositions of the first glaze and the second glaze, in terms of mass percentage of oxides, include: SiO2: 54.11%, Al2O3: 24.06%, Fe2O3: 0.25%, CaO: 2.90%, MgO: 0.19%, K2O: 3.59%, Na2O: 2.67%, P2O5: 0.12%, BaO: 0.26%, ZrO2: 9.29%, and loss on ignition 2.45%. The specific gravity of the first glaze is 1.81 g / mL; the specific gravity of the second glaze is 1.52 g / mL, and the spraying amount of the second glaze is 85 g / (300*600 pans). S3, inkjet printing a color pattern on the digital mold effect layer to form a pattern layer; S4. Screen-printing a color-enhancing glaze on the pattern layer to form a color-enhancing glaze layer; this is done using three layers of screen printing; the mesh size of the screen is 180. The first layer of screen-printing materials comprises, by weight, 100 parts of a basic glaze and 4 parts of a bright red pigment; the second layer of screen-printing materials comprises, by weight, 100 parts of a basic glaze, 0.4 parts of a peach pigment, 0.3 parts of a dark brown pigment, and 0.1 parts of a cobalt black pigment; and the third layer of screen-printing materials comprises, by weight, 100 parts of a basic glaze, 4 parts of an iron red pigment, and 0.12 parts of a cobalt black pigment. The chemical composition of the basic glaze, in terms of the mass percentage of oxides, includes: SiO2: 48.43%, Al2O3: 19.76%, Fe2O3: 0.19%, CaO: 11.57%, MgO: 2.99%, K2O: 0.65%, Na2O: 2.64%, BaO: 1.67%, ZnO: 4.52% and ignition loss 7.44%; S5. Inkjet printing positioning glue on the color-enhancing glaze layer and applying positioning dry particles to form a positioning dry particle layer; wherein the chemical composition of the dry particles, in terms of mass percentage of oxides, comprises: SiO2: 45.10%, Al2O3: 19.38%, CaO: 7.13%, MgO: 2.12%, K2O: 4.53%, Na2O: 0.61%, BaO: 12.02%, ZnO: 6.83%, SrO: 1.75%, and loss on ignition: 0.35%; the amount of dry particles used is 70 g / (300*600 trays); S6. Spraying a dry granular protective glaze onto the positioned dry granular layer to form a protective glaze layer; wherein the chemical composition of the dry granular protective glaze, in percentage by mass of oxides, comprises: SiO2: 52.90%, Al2O3: 17.41%, CaO: 6.66%, MgO: 1.25%, K2O: 3.87%, Na2O: 2.40%, BaO: 6.78%, ZnO: 4.40%, SrO: 4.08%, and loss on ignition: 0.10%. The dry granular protective glaze is applied in an amount of 31 g / (300*600 pans).

[0036] S7: Place the tile in a kiln for firing at 1227°C for a period of 63.66 minutes. The fired semi-finished tile is then polished using ten sets of 1000-mesh abrasive brushes, six sets of 80-mesh hard sponge brushes, and six sets of 120-mesh matte abrasive blocks. The result is a tile with a digital embossed effect.

[0037] Example 3 A method for preparing a ceramic tile with a digital concave-convex effect comprises the following steps: S1, pressing the powder into a brick to form a body layer; S2. On the green body layer, a first glaze, inkjet-printed digital mold ink, and a second glaze are sequentially applied. The drying temperatures are sequentially set to 130° C., 160° C., and 210° C. to form a digital mold effect layer after drying. The chemical compositions of the first glaze and the second glaze, in terms of mass percentage of oxides, include: SiO2: 54.11%, Al2O3: 24.06%, Fe2O3: 0.25%, CaO: 2.90%, MgO: 0.19%, K2O: 3.59%, Na2O: 2.67%, P2O5: 0.12%, BaO: 0.26%, ZrO2: 9.29%, and loss on ignition 2.45%. The specific gravity of the first glaze is 1.81 g / mL; the specific gravity of the second glaze is 1.52 g / mL, and the spraying amount of the second glaze is 85 g / (300*600 pans). S3, inkjet printing a color pattern on the digital mold effect layer to form a pattern layer; S4. Screen-printing a color-enhancing glaze on the pattern layer to form a color-enhancing glaze layer; this is done using three layers of screen printing; the mesh size of the screen is 180. The first layer of screen-printing materials comprises, by weight, 100 parts of a basic glaze and 4 parts of a bright red pigment; the second layer of screen-printing materials comprises, by weight, 100 parts of a basic glaze, 0.4 parts of a peach pigment, 0.3 parts of a dark brown pigment, and 0.1 parts of a cobalt black pigment; and the third layer of screen-printing materials comprises, by weight, 100 parts of a basic glaze, 4 parts of an iron red pigment, and 0.12 parts of a cobalt black pigment. The chemical composition of the basic glaze, in terms of the mass percentage of oxides, includes: SiO2: 48.43%, Al2O3: 19.76%, Fe2O3: 0.19%, CaO: 11.57%, MgO: 2.99%, K2O: 0.65%, Na2O: 2.64%, BaO: 1.67%, ZnO: 4.52% and ignition loss 7.44%; S5. Inkjet printing positioning glue on the color-enhancing glaze layer and applying positioning dry particles to form a positioning dry particle layer; wherein the chemical composition of the dry particles, in terms of mass percentage of oxides, comprises: SiO2: 49.42%, Al2O3: 18.10%, Fe2O3: 0.10%, CaO: 7.44%, MgO: 1.82%, K2O: 4.39%, Na2O: 1.39%, BaO: 8.01%, ZnO: 5.64%, SrO: 3.31%, and loss on ignition: 0.27%; the amount of dry particles used is 70 g / (300*600 trays); S6. Spray a dry granular protective glaze onto the positioned dry granular layer to form a protective glaze layer. The chemical composition of the dry granular protective glaze, in percentage by mass of oxides, includes: SiO2: 43.70%, Al2O3: 20.59%, Fe2O3: 0.18%, CaO: 6.34%, MgO: 2.93%, K2O: 1.48%, Na2O: 2.31%, BaO: 10.16%, ZnO: 2.47%, and loss on ignition: 9.66%. The dry granular protective glaze is applied in an amount of 31 g / (300 x 600 pans).

[0038] S7: Place the tile in a kiln for firing at 1227°C for a period of 63.66 minutes. The fired semi-finished tile is then polished using ten sets of 1000-mesh abrasive brushes, six sets of 80-mesh hard sponge brushes, and six sets of 120-mesh matte abrasive blocks. The result is a tile with a digital embossed effect.

[0039] Example 4 A method for preparing a ceramic tile with a digital concave-convex effect comprises the following steps: S1, pressing the powder into a brick to form a body layer; S2. On the green body layer, a first glaze, inkjet-printed digital mold ink, and a second glaze are sequentially applied. The drying temperatures are sequentially set to 130° C., 160° C., and 210° C. to form a digital mold effect layer after drying. The chemical compositions of the first glaze and the second glaze, in terms of mass percentage of oxides, include: SiO2: 54.11%, Al2O3: 24.06%, Fe2O3: 0.25%, CaO: 2.90%, MgO: 0.19%, K2O: 3.59%, Na2O: 2.67%, P2O5: 0.12%, BaO: 0.26%, ZrO2: 9.29%, and loss on ignition 2.45%. The specific gravity of the first glaze is 1.81 g / mL; the specific gravity of the second glaze is 1.52 g / mL, and the spraying amount of the second glaze is 85 g / (300*600 pans). S3, inkjet printing a color pattern on the digital mold effect layer to form a pattern layer; S4. Screen-printing a color-enhancing glaze on the pattern layer to form a color-enhancing glaze layer; this is done using three layers of screen printing; the mesh size of the screen is 180. The first layer of screen-printing materials comprises, by weight, 100 parts of a basic glaze and 4 parts of a bright red pigment; the second layer of screen-printing materials comprises, by weight, 100 parts of a basic glaze, 0.4 parts of a peach pigment, 0.3 parts of a dark brown pigment, and 0.1 parts of a cobalt black pigment; and the third layer of screen-printing materials comprises, by weight, 100 parts of a basic glaze, 4 parts of an iron red pigment, and 0.12 parts of a cobalt black pigment. The chemical composition of the basic glaze, in terms of the mass percentage of oxides, includes: SiO2: 48.43%, Al2O3: 19.76%, Fe2O3: 0.19%, CaO: 11.57%, MgO: 2.99%, K2O: 0.65%, Na2O: 2.64%, BaO: 1.67%, ZnO: 4.52% and ignition loss 7.44%; S5. Inkjet printing positioning glue on the color-enhancing glaze layer and applying positioning dry particles to form a positioning dry particle layer; wherein the chemical composition of the dry particles, in terms of mass percentage of oxides, comprises: SiO2: 49.42%, Al2O3: 18.10%, Fe2O3: 0.10%, CaO: 7.44%, MgO: 1.82%, K2O: 4.39%, Na2O: 1.39%, BaO: 8.01%, ZnO: 5.64%, SrO: 3.31%, and loss on ignition: 0.27%; the amount of dry particles used is 70 g / (300*600 trays); S6. Spray a dry granular protective glaze onto the positioned dry granular layer to form a protective glaze layer. The chemical composition of the dry granular protective glaze, in percentage by mass of oxides, comprises: SiO2: 52.90%, Al2O3: 17.41%, CaO: 6.66%, MgO: 1.25%, K2O: 3.87%, Na2O: 2.40%, BaO: 6.78%, ZnO: 4.40%, SrO: 4.08%, and ignition loss: 0.10%. The dry granular protective glaze is applied in an amount of 31 g / (300 x 600 pans).

[0040] S7: Place the tile in a kiln for firing at 1227°C for a period of 63.66 minutes. The fired semi-finished tile is then polished using ten sets of 1000-mesh abrasive brushes, six sets of 80-mesh hard sponge brushes, and six sets of 120-mesh matte abrasive blocks. The result is a tile with a digital embossed effect.

[0041] Comparative Example 1 This comparative example adopts the same preparation method as Example 4, with the only difference being that, in terms of the mass percentage of oxides, the chemical compositions of the first glaze and the second glaze include: SiO2: 50.93%, Al2O3: 21.01%, Fe2O3: 0.20%, CaO: 8.60%, MgO: 3.67%, K2O: 1.69%, Na2O: 1.97%, BaO: 1.96%, ZnO: 0.96%, ZrO2: 0.38% and loss on ignition 8.44%.

[0042] Comparative Example 2 This comparative example adopts the same preparation method as Example 4, except that: the chemical composition of the dry particles, calculated in percentage by mass of oxides, includes: SiO2: 52.35%, Al2O3: 17.43%, Fe2O3: 0.11%, CaO: 7.70%, MgO: 1.62%, K2O: 4.34%, Na2O: 1.99%, TiO2: 0.02%, BaO: 5.20%, ZnO: 4.53%, SrO: 4.19%, and loss on ignition: 0.45%.

[0043] Comparative Example 3 This comparative example adopts the same preparation method as Example 4, with the only difference being that, in terms of the mass percentage of oxides, the chemical composition of the dry particle protective glaze includes: SiO2: 53.35%, Al2O3: 17.50%, CaO: 3.13%, K2O: 2.58%, Na2O: 3.53%, BaO: 11.78%, ZnO: 4.09%, SrO: 3.70%, and ignition loss of 0.13%.

[0044] The tiles prepared in Examples 1 to 4 and Comparative Examples 1 to 3 were tested using the following standards and methods: 1. Raised effect: judge the raised effect and texture of the tile surface by touching it with your hands.

[0045] 2. Pattern texture effect: Observe the effect of peeling off the concave area of ​​the pattern texture, and the effect of texture undulation and transition through human eyes.

[0046] 3. Antifouling: Refer to the national standard GB / T 3810.14-2016 to test the antifouling performance of the ceramic tile surface. The staining agent (such as chromium green, iodine or olive oil) is brought into contact with the tile surface and allowed to act for a period of time. Then, the tile surface is cleaned according to the prescribed cleaning method. The changes on the tile surface are observed to determine the stain resistance level of the tile. There are 1 to 5 levels in total, and level 5 has the highest stain resistance.

[0047] 4. Abrasion Resistance: The wear resistance of ceramic tile surfaces was tested in accordance with the national standard GB / T 3810.7-2014. The wear of the tile surface at a specific grinding revolution was observed on a scale of 0 to 5. Visible wear after 100 revolutions was designated as Level 0, visible wear after 150 revolutions as Level 1, visible wear after 600 revolutions as Level 2, visible wear after 750 / 1500 revolutions as Level 3, visible wear after 2100 / 6000 / 12000 revolutions as Level 4, and visible wear after more than 12000 revolutions as Level 5.

[0048] 5. Overall satisfaction: This is achieved by comprehensively evaluating the tile surface's anti-fouling performance, pattern and texture, feel, and texture, and scoring it on a scale of 1 to 5, with 1 indicating very dissatisfied, 2 indicating dissatisfied, 3 indicating average, 4 indicating satisfied, and 5 indicating very satisfied.

[0049] The test results are shown in Table 1.

[0050] Table 1 As shown in Table 1, the ceramic tile surfaces prepared in Examples 1 to 4 have good antifouling and wear resistance, with obvious concave and convex textures and good natural transitions. The ceramic tile surfaces have a good feel and good overall texture, and the satisfaction rate can reach more than 4 points. Among them, the technical solution of Example 4 is the best. Figures 1-3 As shown, the deep ink and light transition ink have obvious separation effect, the pattern texture is fine, clear and the transition is natural, the convex effect is obvious and the undulation transition is good, the hand feel is smooth, and the anti-fouling and wear resistance are at their best. Figure 4 As shown, the ceramic tile prepared in Example 4 has a refined ceramic tile texture. Through observation under a microscope, it can be seen that the texture width is 45~60μm, and the height difference of the surface bumps can reach 350~400μm. Figure 5It also further demonstrates the richness of the detailed texture of the ceramic tiles under different lighting conditions, with smooth and diverse transitions between convex and concave, presenting a natural and realistic texture. Compared with Example 4, Example 1 uses a different first glaze formula. The first glaze used in Example 1 has slightly poor compatibility with shallow transition inks, resulting in a slightly worse transition undulation of the concave texture than in Example 4, but still retains a certain degree of undulation. The first glaze has a lower melting temperature than the second glaze, resulting in a brighter effect in the concave area. This shows that the combination of the first glaze and the second glaze formula in Example 4 can achieve a clearer, naturally transitioned texture with the best effect. Comparing Example 2 with Example 4, the ceramic tile surface produced by the dry granular formula used in Example 2 has a general raised effect and a more obvious undulation, indicating that the dry granular formula used in Example 4 has the best raised effect. Comparing Example 3 with Example 4, the ceramic tile surface produced by the dry granular protective glaze formula used in Example 3 has a slightly worse feel than that of Example 4, and feels rougher, indicating that the dry granular protective glaze formula used in Example 4 has the best surface feel.

[0051] In Comparative Example 1, the formula of the first glaze and the second glaze was adjusted. The glaze formula used had poor fluidity and a high clay content, which resulted in insufficient repulsion between the water-based glaze and the hydrophobic ink, resulting in a worse effect of the ink pushing away the glaze, unclear undulations, and poor texture effects.

[0052] The dry granule formula replaced in Comparative Example 2 has poor formability after firing, poor convex effect, and unclear undulation.

[0053] The dry particle protective glaze replaced in Comparative Example 3 has a high melting temperature. When fired together with the dry particles, it cannot provide a smooth channel for the melting and exhaust of the dry particles, thereby increasing the porosity of the glaze surface after firing and deteriorating the anti-fouling performance.

[0054] Comparative Example 4 The same preparation method as in Example 4 was adopted, with the only difference being that in step S2, the drying temperatures were set to 120°C, 140°C, and 180°C, respectively.

[0055] Comparative Example 5 The same preparation method as in Example 4 was adopted, with the only difference being that in step S2, the drying temperatures were set to 150°C, 190°C, and 250°C, respectively.

[0056] The moisture content of the green bodies after drying in step S2 in Example 4 and Comparative Examples 4 and 5 was detected, and the detection results are shown in Table 2.

[0057] Table 2 As shown in Table 2, in Comparative Example 4, when the drying oven temperature is set too low, the moisture content of the green body after drying is consistently high, and the water volatilization rate is slow, causing the moisture to penetrate deep into the green body, which can easily affect the green body strength. For example, in Comparative Example 5, when the drying oven temperature is set too high, the glaze has poor fluidity, the deep ink removal effect is poor, and glaze spots are easily formed in the middle of the concave area. Therefore, the optimal drying temperatures of the present invention are 130-135°C, 160-165°C, and 205-210°C.

[0058] Example 5 The same preparation method as in Example 4 was adopted, except that the material formula of the first screen-printed layer in the color-enhancing glaze layer was adjusted as shown in Table 3 (unit: parts by weight).

[0059] Table 3 Example 6 The same preparation method as in Example 4 was adopted, with the only difference being that the material formula for the second screen-printed layer in the color-enhancing glaze layer was adjusted as shown in Table 4 (unit: parts by weight).

[0060] Table 4 Example 7 The same preparation method as in Example 4 was adopted, except that the material formula for the third screen-printed layer in the color-enhancing glaze layer was adjusted as shown in Table 5 (unit: parts by weight).

[0061] Table 5 The similarity of the texture and color of the glazes of the tiles produced in Examples 4-7 was measured. The similarity was characterized by blindly testing the tiles and the original stone. Twenty testers observed and compared the texture and color effects and the color gradients at the undulations, and selected "different" or "no difference." The percentage of participants who rated "no difference" was calculated (number of participants / total participants * 100%). A percentage below 40% indicated a clear difference between the tile and the original stone; between 40% and 60% indicated a weak difference; above 60% indicated a high degree of similarity; and above 80% indicated an extremely high degree of similarity.

[0062] The test results are shown in Table 6.

[0063] Table 6 As shown in Table 6, by accurately matching the colorant and the basic glaze, the color enhancement glaze scheme of Example 4 can obtain a glaze effect with the best color richness, vividness and realism.

[0064] Example 8 and Comparative Example 6 The same preparation method as in Example 4 was used, differing only in adjusting the specific parameters of the brush-polishing process in step S7 as shown in Tables 7 and 8. The performance parameters and surface quality of the resulting tiles were tested. The surface quality was assessed by sliding a palm flat across the tile surface and measuring the gloss at different locations using a photometer. The test results are shown in Tables 7 and 8.

[0065] Table 7 Table 8 Table 7 shows that the different brushing parameters used in Example 8 have a certain impact on the feel and texture of the tile surface, antifouling properties, and wear resistance. Comparing the effects of various parameters in Example 4 and Example 8, the brushing parameters used in Example 4 are optimal, effectively eliminating the harsh transition between concave and convex areas and achieving optimal surface softness, smoothness, and overall harmony. Table 8 also shows that the brushing parameters used in Comparative Example 6 all exhibited wear-through due to excessive cutting volume.

[0066] The above description is only a preferred embodiment of the present invention and does not limit the patent scope of the present invention. All equivalent structural transformations made by using the contents of the present invention specification under the inventive concept of the present invention, or direct / indirect application in other related technical fields are included in the patent protection scope of the present invention.

Claims

1. A method for preparing ceramic tiles with digital concave-convex effects, characterized in that: The steps include: S1, pressing the powder into a brick to form a body layer; S2, sequentially pouring a first glaze, inkjet printing a digital mold ink, and spraying a second glaze on the green body layer, and forming a digital mold effect layer after drying; S3, inkjet printing a color pattern on the digital mold effect layer to form a pattern layer; S4, screen printing a color-enhancing glaze on the pattern layer to form a color-enhancing glaze layer; S5, inkjet printing positioning glue on the color-enhancing glaze layer, applying positioning dry particles, and forming a positioning dry particle layer; S6, spraying dry particle protective glaze on the positioned dry particle layer to form a protective glaze layer; S7, sending the semi-finished ceramic tile into a kiln for firing, and brushing and polishing the fired semi-finished ceramic tile to obtain a ceramic tile with a digital concave-convex effect.

2. The method for preparing a ceramic tile with digital concave-convex effect according to claim 1, characterized in that: In step S2, the chemical compositions of the first glaze and the second glaze, calculated in percentage by mass of oxides, include: SiO2: 52-57%, Al2O3: 22-26%, Fe2O3: 0.1-0.5%, CaO: 1-5%, MgO: 0.1-0.4%, K2O: 1-5%, Na2O: 1-5%, P2O5: 0.1-0.3%, BaO: 0.1-0.5%, ZrO2: 7-12%, and ignition loss of 1-5%; In step S5, the chemical composition of the dry particles, in terms of percentage by mass of oxides, includes: SiO2: 47-50%, Al2O3: 15-20%, Fe2O3: 0.05-0.2%, CaO: 5-10%, MgO: 1-5%, K2O: 2-7%, Na2O: 1-4%, BaO: 7-10%, ZnO: 3-7%, SrO: 1-5%, and loss on ignition 0.1-0.5%; In step S6, the chemical composition of the dry particle protective glaze, calculated in percentage by mass of oxides, includes: SiO2: 50-55%, Al2O3: 15-20%, CaO: 5-10%, MgO: 1-4%, K2O: 2-5%, Na2O: 1-5%, BaO: 5-10%, ZnO: 2-7%, SrO: 2-6%, and ignition loss of 0.05-0.3%.

3. The method for preparing a ceramic tile with digital concave-convex effect according to claim 1, characterized in that: In step S2, the specific gravity of the first glaze is 1.80-1.90 g / mL, the specific gravity of the second glaze is 1.52±0.01 g / mL, and the spraying amount of the second glaze is 85±1 g / (300*600 pans).

4. The method for preparing a ceramic tile with digital concave-convex effect according to claim 1, characterized in that: In step S2, the drying temperatures are set to 130-135°C, 160-165°C, and 205-210°C, respectively.

5. The method for preparing a ceramic tile with digital concave-convex effect according to claim 1, characterized in that: In step S4, the color-enhancing glaze layer is formed by three-layer screen printing; The first layer of screen printing materials includes, by mass, 100 parts of basic glaze and 4 parts of bright red pigment; the second layer of screen printing materials includes, by mass, 100 parts of basic glaze, 0.4 parts of peach pigment, 0.3 parts of dark brown pigment, and 0.1 parts of cobalt black pigment; the third layer of screen printing materials includes, by mass, 100 parts of basic glaze, 4 parts of iron red pigment, and 0.12 parts of cobalt black pigment; The chemical composition of the basic glaze, calculated in percentage by mass of oxides, includes: SiO2: 45-50%, Al2O3: 17-22%, Fe2O3: 0.1-0.4%, CaO: 10-15%, MgO: 1-5%, K2O: 0.5-1.0%, Na2O: 1-5%, BaO: 1-4%, ZnO: 2-7% and an ignition loss of 5-10%.

6. The method for preparing a ceramic tile with digital concave-convex effect according to claim 1, characterized in that: In step S5, the amount of dry particles used is 70±1 g / (300*600 plates).

7. The method for preparing a ceramic tile with digital concave-convex effect according to claim 1, characterized in that: In step S6, the glazing amount of the dry particle protective glaze is 31±1 g / (300*600 pans).

8. The method for preparing a ceramic tile with digital concave-convex effect according to claim 1, characterized in that: In step S7, the firing temperature is 1200-1230° C., and the firing period is 63-67 minutes.

9. The method for preparing a ceramic tile with digital concave-convex effect according to claim 1, characterized in that: The brush polishing parameters are 10 groups of 1000 mesh abrasive brushes, 6 groups of 80 mesh hard sponge brushes and 6 groups of 120 mesh matte grinding blocks.

10. A ceramic tile with digital concave-convex effect, characterized in that: The ceramic tile with digital concave-convex effect is prepared by the preparation method of any one of claims 1 to 9.

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