Ceramic dry material, preparation method and ceramic tile

Abstract

The invention belongs to the technical field of ceramic materials, and particularly discloses a dry ceramic material, a preparation method and a ceramic tile, the dry ceramic material comprises the following raw materials: 92-96 parts of waste glaze, 0.5-2 parts of an inorganic binder, 2-3 parts of an organic binder and 0.5-21.5 parts of a pigment; the specific preparation method comprises the following steps: uniformly mixing the raw materials, carrying out spray granulation at 600-680 DEG C, then carrying out semi-sintering at 850-950 DEG C, and carrying out heat preservation at 300 DEG C after the semi-sintering is completed; the invention also discloses a ceramic tile using the ceramic dry material in the preparation process. According to the invention, the waste glaze is used as a main component of the raw material in a breakthrough manner, and a specific preparation method is created, so that the problem of recycling of the waste glaze is solved, the production cost is reduced, and the environmental protection effect is improved; the ceramic dry material provided by the invention is insoluble in the glaze slip at normal temperature and is suspended in the glaze slip, so that the dry particles are uniformly distributed in the glaze slip, holes are prevented from being formed in the surface in the subsequent building material firing process, and the product quality is improved.

Description

Technical Field

[0001] The present application belongs to the technical field of ceramic materials, and specifically relates to a ceramic dry material and a preparation method, and ceramic tiles. Background Art

[0002] Ceramic raw materials are non-renewable minerals, and a large amount of glaze slurry will be wasted due to various reasons during the production process. Most ceramic factories flush the remaining slurry into other glaze slurries for processing. However, this method often has a certain impact on other products. There are certain uncontrollable factors in production. The technology of replacing existing starlight dry particles with colored particles is not mature enough. The colors required for existing colored three-dimensional bricks are often in the form of dry material blocks, which greatly increases the production cost.

[0003] At present, ceramic glaze products generally have a single surface effect. Starry sky glaze products also have dry particles mixed in the glaze. After polishing, tiny pinholes are easily generated, which have a certain impact on the product's stain resistance. The uneven mixing and easy precipitation of dry particles are also a major reason for the unstable production of starry sky glaze. The traditional method of dealing with waste glaze is to add the remaining glaze to other glazes and reuse it. This may contaminate the existing product glaze and cause production defects. The cost of purchasing dry particle blocks of various colors to make three-dimensional starlight tiles is relatively high. Summary of the Invention

[0004] The purpose of this application is to address the deficiencies of the prior art and provide a ceramic dry material and preparation method, as well as ceramic tiles, specifically adopting the following technical solutions: First, the present application provides a ceramic dry material, the raw materials of which include, by weight: 92-96 parts of waste glaze, 0.5-2 parts of inorganic binder, 2-3 parts of organic binder and 0.5-21.5 parts of colorant; the decomposition temperature of the organic binder is 200℃-400℃.

[0005] In this application, the applicant has conducted extensive exploration and research on the recycling and reuse of waste glazes currently occurring in ceramic production. Since waste glazes are waste generated in ceramic production, and the composition of the glazes selected for different batches of ceramics during the production process is different, many considerations need to be taken into account during the reuse process to avoid the various problems caused by the uneven composition of the complex mixed components during the reuse process.

[0006] Therefore, in the present application, the applicant overcame numerous difficulties and proposed a new solution for the reuse of such waste glaze slurry. The waste glaze slurry was made into a specific microporous structure through specific technical means, so that its density was within an appropriate range, so that it was insoluble in the newly prepared ceramic tile glaze layer, and at the same time, it could hover at a specific position in the glaze layer, thereby better realizing the starlight effect on the surface. At the same time, it avoided the problem of tiny pinholes easily generated after subsequent polishing due to suspension on the surface, thereby achieving the dry material prepared by the waste glaze recycling method provided in the present application with excellent production effect and economic value. In addition, it also has the effect of reducing pollution discharge and thus being environmentally friendly and sustainable, realizing the dual significance of economic value and social value.

[0007] Furthermore, the organic binder is non-ionic cellulose mixed ether.

[0008] In the present application, the addition of non-ionic cellulose mixed ether is to enable fine and precise micropores under specific conditions, thereby adjusting the prepared dry particles to achieve hovering in the new glaze while also having excellent starry sky reflection and color effects.

[0009] In the present application, the applicant discovered that by specifically selecting a non-ionic cellulose mixed ether with a decomposition temperature of 200°C-400°C, it is possible to achieve sufficient mixing during the production process and generate uniform and tiny pores during the sintering process, thereby achieving specific control over the product's hovering characteristics.

[0010] In some specific embodiments, the organic binder is hydroxypropyl methylcellulose.

[0011] In the specific embodiments of the present application, hydroxypropyl methylcellulose is used as an example. However, hydroxypropyl methylcellulose is not the only option that can achieve the technical effects provided by the present application.

[0012] Furthermore, by weight, the colorant includes at least one of 2-5 parts of ancient black material G40, 0.5-1 part of light red material D10, 1-3 parts of brown yellow material D30, 1-3 parts of gray material D22, 1-3 parts of phantom gray E26, 0.5-1.5 parts of light yellow material S37, 0.5-2 parts of brown red material D31, and 1-3 parts of super white material B13.

[0013] In this application, in order to meet users' needs for different colors, the applicant provides a larger colorant adjustment space in the formula, thereby providing a larger space for the richness of products in actual production.

[0014] Furthermore, the inorganic binder includes water glass and aluminum dihydrogen phosphate.

[0015] Inorganic binders give the dry particles a certain strength after spray granulation and semi-sintering at 600-1000°C, making them less likely to break during transportation, which would affect the particle quality. Common inorganic binders include silica sol, alumina sol, etc.

[0016] In this application, in order to achieve a specific hovering effect for the recycling of waste glaze, water glass and aluminum dihydrogen phosphate need to be selected in a specific proportion under the premise of a composite specific processing technology, so as to achieve a specific effect while meeting the strength requirements; at the same time, in order to improve the mechanical properties and improve the microstructure, so that the glaze and the dry material provided in this application are more closely combined, aluminum dihydrogen phosphate is also selected to be added.

[0017] Furthermore, the raw materials also include 1-2 parts by weight of zirconium silicate, which is an emulsifier for the white glaze particles.

[0018] In some specific embodiments, the chemical composition of the ceramic dry material includes: SiO2: 52.14%-55.12%, Al2O3: 14.64%-18.36%, MgO: 2.35%-4.54%, CaO: 6.11%-8.85%, Na2O: 2.75%-4.75%, K2O: 0.19%-0.59%, BaO: 3.41%-5.52%, ZnO: 4.43%-6.36%, SO3: 1.22%-2.63%, and the balance is loss on ignition and a small amount of impurities.

[0019] Secondly, the present application also provides a method for preparing the above-mentioned ceramic dry material, comprising: mixing the raw materials, spray granulating at 600℃-680℃, and then semi-sintering at 850℃-950℃, with a semi-sintering time of 4 minutes.

[0020] The present application firstly mixes the above-mentioned specific raw materials (to obtain the material) and then atomizes and granulates them. During this process, since the decomposition temperature of the organic binder is between 200°C and 400°C, the above-mentioned organic binder can volatilize in the above-mentioned specific material to form honeycomb-shaped pores during the spray granulation process at 600°C to 680°C, thereby reducing the density of the material particles, making it difficult for the material particles to precipitate in the glaze slurry system during subsequent processing; secondly, the initial particles obtained by spray granulation are semi-sintered at a specific temperature, which can make the particles insoluble in water glaze in later production, thereby ensuring the three-dimensional effect of the particles.

[0021] In some more preferred schemes, the above-mentioned semi-sintering process is carried out in a blast kiln, specifically: the initial particles obtained by spray granulation are added to the blast kiln, and the primary particles are blown by a blower to be suspended in the blast kiln, so that the primary particles are in a uniformly dispersed state, and sintering is carried out at this time, so that the primary particles are in a suspended heating state, so that they are heated evenly, sintering is more uniform, and the quality of the obtained ceramic dry material is better.

[0022] Furthermore, after the heat preservation, the product is screened through an 80-100 mesh sieve.

[0023] In the present application, the applicant has achieved sintering of the above-mentioned specific raw materials through precise control of a specific sintering process, thereby achieving the goal of providing dry particles with a specific microporous structure while having excellent hardness, color, visual effects, and suspension effects brought about by a specific density. In addition, the dry particles formed by this preparation method in the present application also have excellent other performance indicators, the specific details of which will be disclosed in detail in the subsequent specific implementation methods.

[0024] In some specific embodiments, the specific preparation method of the above-mentioned ceramic dry material includes: mixing 95 parts of waste glaze, 1 part of inorganic binder, 2 parts of organic binder, 1 part of zirconium silicate, and 1 part of colorant by weight, spray granulating at 600°C, and then semi-sintering at 850°C-950°C for 4 minutes. After completing semi-sintering, the temperature is reduced to 300°C and kept warm for 5 minutes.

[0025] Finally, the present application also provides a ceramic tile, which comprises, from bottom to top, a brick blank, a glaze layer, a printing layer and a dry particle layer. The dry particle layer is formed by a dry particle slurry, and the dry particle slurry includes the above-mentioned ceramic dry material.

[0026] The beneficial effects of the present application are as follows: the present application has made a breakthrough in using waste glaze as the main component of the raw material, and has pioneered a specific preparation method, which not only solves the problem of recycling waste glaze, but also reduces production costs and improves environmental protection effects; the ceramic dry material provided by the present application is insoluble in the glaze slurry at room temperature and is suspended in the glaze slurry, so that the dry particles are evenly distributed in the glaze slurry, avoiding the appearance of holes on the surface during the subsequent building material firing process, thereby improving product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 Shown is a real photo of a ceramic dry material in the embodiment; Figure 2 Shown is a physical photograph of another ceramic dry material in the embodiment; Figure 3 The tiles prepared in Example 1; Figure 4 This is the tile prepared in Example 2.

[0028] Figure 5 This is the performance diagram of the dry granular slurry glaze slurry in Example 1 Figure 6 The dry slurry performance diagram of comparative example 3 Figure 7 The dry slurry performance diagram of comparative example 6 DETAILED DESCRIPTION The following will be combined with the embodiments and drawings to clearly and completely describe the concept and technical effects of this application so as to fully understand the purpose, scheme and effect of this application. It should be noted that the embodiments and features in the embodiments of this application can be combined with each other unless there is a conflict.

[0029] In a specific embodiment of the present application, black material, phantom gray and gray material are purchased from Foshan Hengbao Ceramic Chemical Co., Ltd., light red material and brown red material are purchased from Foshan Yuanse New Material Co., Ltd., and light yellow material and ultra-white material are purchased from Foshan Qianhong Inorganic Materials Co., Ltd.

[0030] Example 1 First, this embodiment provides a ceramic dry material, the raw materials of which include 95 parts of waste glaze, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio 1:3), 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of ultra-white material B13.

[0031] Secondly, this embodiment also provides a method for preparing a corresponding ceramic dry material, comprising the following steps: In parts by weight, 95 parts of waste glaze for preparing ceramic dry material, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio of 1:3), 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of ultra-white material B13 are stirred and mixed, and the addition of water is properly controlled to prepare the raw material slurry. The slurry is prepared to a water content of 30% and a slurry fineness of 1.0. The prepared slurry is then transported to a spray tower through a Huayan pump for granulation treatment. After being fired at 600°C in the spray tower, honeycomb fine-porous particles are obtained.

[0032] The fine-porous particles were added into a blast frit furnace through a screw feeder and heated at a temperature of 870°C for 4 minutes for semi-sintering. The temperature was then lowered to 300°C and kept at this temperature for 5 minutes. The blower was then turned off to allow the dry particles to fall freely into a recovery device and pass through a 100-mesh sieve to obtain white particles.

[0033] Subsequently, this embodiment further provides a ceramic tile comprising the ceramic dry material, which comprises, from bottom to top, a brick blank, a glaze layer, a printing layer, and a dry particle layer, wherein the dry particle layer is formed by a dry particle slurry, and the dry particle slurry includes the ceramic dry material; and a preparation method thereof comprises the following steps: The bricks are prepared, glazed after drying, and then printed. After printing, the dry granular slurry made of the ceramic dry material provided in this embodiment is poured on the surface, sent to the kiln, fired at 1220°C, and then polished and graded to obtain ceramic tiles.

[0034] Example 2 First, this embodiment provides a ceramic dry material, the raw materials of which include 95 parts of waste glaze, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio 1:3), 2 parts of hypromellose and 2 parts of brown material D30.

[0035] Secondly, this embodiment also provides a method for preparing a corresponding ceramic dry material, comprising the following steps: In parts by weight, 95 parts of waste glaze for preparing ceramic dry materials, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio 1:3), 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 2 parts of brown material D30 are stirred and evenly mixed, and the addition of water is properly controlled to prepare the raw material slurry. The slurry is prepared to a water content of 30% and a slurry fineness of 1.0. The prepared slurry is then transported to a spray tower through a Huayan pump for granulation treatment. After being fired at 600°C in the spray tower, honeycomb fine-porous particles are obtained.

[0036] The fine-porous particles were added into a blast frit furnace through a screw feeder and heated at a temperature of 870°C for 4 minutes for semi-sintering. The temperature was then lowered to 300°C and kept at this temperature for 5 minutes. The blower was then turned off to allow the dry particles to fall freely into a recovery device and pass through a 100-mesh sieve to obtain white particles.

[0037] Subsequently, this embodiment further provides a ceramic tile comprising the ceramic dry material, which comprises, from bottom to top, a brick blank, a glaze layer, a printing layer, and a dry particle layer, wherein the dry particle layer is formed by a dry particle slurry, and the dry particle slurry includes the ceramic dry material; and a preparation method thereof comprises the following steps: The bricks are prepared, glazed after drying, and then printed. After printing, the dry granular slurry made of the ceramic dry material provided in this embodiment is poured on the surface, sent to the kiln, fired at 1220°C, and then polished and graded to obtain ceramic tiles.

[0038] Example 3 First, this embodiment provides a ceramic dry material, the raw materials of which include 95 parts of waste glaze, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio 1:3), 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 3 parts of ash B22.

[0039] Secondly, this embodiment also provides a method for preparing a corresponding ceramic dry material, comprising the following steps: In parts by weight, 95 parts of waste glaze for preparing ceramic dry materials, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio of 1:3), 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 3 parts of ash B22 are stirred and mixed, and the addition of water is properly controlled to prepare the raw material slurry. The slurry is prepared to a water content of 30% and a slurry fineness of 1.15. The prepared slurry is then transported to a spray tower through a Huayan pump for granulation treatment. After being fired at 600°C in the spray tower, honeycomb fine-porous particles are obtained.

[0040] The fine-porous particles were added into a blast frit furnace through a screw feeder and heated at a temperature of 870°C for 4 minutes for semi-sintering. The temperature was then lowered to 300°C and kept at this temperature for 5 minutes. The blower was then turned off to allow the dry particles to fall freely into a recovery device and pass through a 100-mesh sieve to obtain white particles.

[0041] Subsequently, this embodiment further provides a ceramic tile comprising the ceramic dry material, which comprises, from bottom to top, a brick blank, a glaze layer, a printing layer, and a dry particle layer, wherein the dry particle layer is formed by a dry particle slurry, and the dry particle slurry includes the ceramic dry material; and a preparation method thereof comprises the following steps: The bricks are prepared, glazed after drying, and then printed. After printing, the dry granular slurry made of the ceramic dry material provided in this embodiment is poured on the surface, sent to the kiln, fired at 1220°C, and then polished and graded to obtain ceramic tiles.

[0042] Example 4 First, this embodiment provides a ceramic dry material, the raw materials of which include 95 parts of waste glaze, 0.5 parts of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio of 1:3), 2 parts of hypromellose, 1 part of zirconium silicate and 1 part of super white material B13.

[0043] Secondly, this embodiment also provides a method for preparing a corresponding ceramic dry material, comprising the following steps: In parts by weight, 95 parts of waste glaze for preparing ceramic dry material, 0.5 parts of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio of 1:3), 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of ultra-white material B13 are stirred and mixed, and the addition of water is properly controlled to prepare the raw material slurry. The slurry is prepared to a water content of 30% and a slurry fineness of 1.1. The prepared slurry is then transported to a spray tower through a Huayan pump for granulation treatment. After being fired at 600°C in the spray tower, honeycomb fine-porous particles are obtained.

[0044] The fine-porous particles were added into a blast frit furnace through a screw feeder and heated at a temperature of 870°C for 4 minutes for semi-sintering. The temperature was then lowered to 300°C and kept at this temperature for 5 minutes. The blower was then turned off to allow the dry particles to fall freely into a recovery device and pass through a 100-mesh sieve to obtain white particles.

[0045] Subsequently, this embodiment further provides a ceramic tile comprising the ceramic dry material, which comprises, from bottom to top, a brick blank, a glaze layer, a printing layer, and a dry particle layer, wherein the dry particle layer is formed by a dry particle slurry, and the dry particle slurry includes the ceramic dry material; and a preparation method thereof comprises the following steps: The bricks are prepared, glazed after drying, and then printed. After printing, the dry granular slurry made of the ceramic dry material provided in this embodiment is poured on the surface, sent to the kiln, fired at 1220°C, and then polished and graded to obtain ceramic tiles.

[0046] Example 5 First, this embodiment provides a ceramic dry material, the raw materials of which include 95 parts of waste glaze, 2 parts of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio 1:3), 2 parts of hypromellose, 1 part of zirconium silicate and 1 part of ultra-white material B13.

[0047] Secondly, this embodiment also provides a method for preparing a corresponding ceramic dry material, comprising the following steps: In parts by weight, 95 parts of waste glaze for preparing ceramic dry material, 2 parts of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio of 1:3), 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of ultra-white material B13 are stirred and mixed, and the addition of water is properly controlled to prepare the raw material slurry. The slurry is prepared to a water content of 30% and a slurry fineness of 1.15. The prepared slurry is then transported to a spray tower through a Huayan pump for granulation treatment. After being fired at 600°C in the spray tower, honeycomb fine-porous particles are obtained.

[0048] The fine-porous particles are added to a blast frit furnace through a screw feeder and heated at a temperature of 850°C-950°C for 4 minutes for semi-sintering. The temperature is then lowered to 300°C and kept warm for 5 minutes. The blower is then turned off to allow the dry particles to fall freely into a recovery device and pass through a 100-mesh sieve to obtain white particles.

[0049] Subsequently, this embodiment further provides a ceramic tile comprising the ceramic dry material, which comprises, from bottom to top, a brick blank, a glaze layer, a printing layer, and a dry particle layer, wherein the dry particle layer is formed by a dry particle slurry, and the dry particle slurry includes the ceramic dry material; and a preparation method thereof comprises the following steps: The bricks are prepared, glazed after drying, and then printed. After printing, the dry granular slurry made of the ceramic dry material provided in this embodiment is poured on the surface, sent to the kiln, fired at 1220°C, and then polished and graded to obtain ceramic tiles.

[0050] Example 6 First, this embodiment provides a ceramic dry material, whose raw materials include 95 parts of waste glaze, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio 1:3), 3 parts of hypromellose, 1 part of zirconium silicate and 1 part of ultra-white material B13.

[0051] Secondly, this embodiment also provides a method for preparing a corresponding ceramic dry material, comprising the following steps: In parts by weight, 95 parts of waste glaze for preparing ceramic dry material, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio of 1:3), 3 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of ultra-white material B13 are stirred and mixed, and the addition of water is properly controlled to prepare the raw material slurry. The slurry is prepared to a water content of 30% and a slurry fineness of 1.0. The prepared slurry is then transported to a spray tower through a Huayan pump for granulation treatment. After being fired at 600°C in the spray tower, honeycomb fine-porous particles are obtained.

[0052] The fine-porous particles were added into a blast frit furnace through a screw feeder and heated at a temperature of 870°C for 4 minutes for semi-sintering. The temperature was then lowered to 300°C and kept at this temperature for 5 minutes. The blower was then turned off to allow the dry particles to fall freely into a recovery device and pass through a 100-mesh sieve to obtain white particles.

[0053] Subsequently, this embodiment further provides a ceramic tile comprising the ceramic dry material, which comprises, from bottom to top, a brick blank, a glaze layer, a printing layer, and a dry particle layer, wherein the dry particle layer is formed by a dry particle slurry, and the dry particle slurry includes the ceramic dry material; and a preparation method thereof comprises the following steps: The bricks are prepared, glazed after drying, and then printed. After printing, the dry granular slurry made of the ceramic dry material provided in this embodiment is poured on the surface, sent to the kiln, fired at 1220°C, and then polished and graded to obtain ceramic tiles.

[0054] Comparative Example 1 First, this comparative example provides a ceramic dry material, the raw materials of which include 95 parts of waste glaze, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio 1:3), 5 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of super white material B13.

[0055] Secondly, this comparative example also provides a preparation method of a corresponding ceramic dry material system, comprising the following steps: In parts by weight, 95 parts of waste glaze for preparing ceramic dry material, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio of 1:3), 5 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of ultra-white material B13 are stirred and mixed, and the addition of water is properly controlled to prepare the raw material slurry. The slurry is prepared to a water content of 30% and a slurry fineness of 1.0. The prepared slurry is then transported to a spray tower through a Huayan pump for granulation treatment. After being fired at 600°C in the spray tower, honeycomb fine-porous particles are obtained.

[0056] The fine-porous particles were added into a blast frit furnace through a screw feeder and heated at a temperature of 870°C for 4 minutes for semi-sintering. The temperature was then lowered to 300°C and kept at this temperature for 5 minutes. The blower was then turned off to allow the dry particles to fall freely into a recovery device and pass through a 100-mesh sieve to obtain white particles.

[0057] Subsequently, this comparative example also provides a ceramic tile comprising the ceramic dry material, which comprises, from bottom to top, a brick blank, a glaze layer, a printing layer, and a dry particle layer, wherein the dry particle layer is formed by a dry particle slurry, and the dry particle slurry includes the ceramic dry material; and the preparation method thereof comprises the following steps: The bricks are prepared, glazed after drying, and then printed. After printing, the dry granular slurry made from the ceramic dry material provided in this comparative example is poured on the surface, sent to the kiln, fired at 1220°C, and then polished and graded to obtain ceramic tiles.

[0058] Comparative Example 2 First, this comparative example provides a ceramic dry material, the raw materials of which include 95 parts of waste glaze, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio 1:3), 0.5 part of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of super white material B13.

[0059] Secondly, this comparative example also provides a preparation method of a corresponding ceramic dry material, comprising the following steps: In parts by weight, 95 parts of waste glaze for preparing ceramic dry material, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio of 1:3), 0.5 part of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of ultra-white material B13 are stirred and mixed, and the addition of water is properly controlled to prepare the raw material slurry. The slurry is prepared to a water content of 30% and a slurry fineness of 1.0. The prepared slurry is then transported to a spray tower through a Huayan pump for granulation treatment. After being fired at 600°C in the spray tower, honeycomb fine-porous particles are obtained.

[0060] The fine-porous particles were added into a blast frit furnace through a screw feeder and heated at a temperature of 870°C for 4 minutes for semi-sintering. The temperature was then lowered to 300°C and kept at this temperature for 5 minutes. The blower was then turned off to allow the dry particles to fall freely into a recovery device and pass through a 100-mesh sieve to obtain white particles.

[0061] Subsequently, this comparative example also provides a ceramic tile comprising the ceramic dry material, which comprises, from bottom to top, a brick blank, a glaze layer, a printing layer, and a dry particle layer, wherein the dry particle layer is formed by a dry particle slurry, and the dry particle slurry includes the ceramic dry material; and the preparation method thereof comprises the following steps: The bricks are prepared, glazed after drying, and then printed. After printing, the dry granular slurry made from the ceramic dry material provided in this comparative example is poured on the surface, sent to the kiln, fired at 1220°C, and then polished and graded to obtain ceramic tiles.

[0062] Comparative Example 3 First, this comparative example provides a ceramic dry material, the raw materials of which include 95 parts of waste glaze, 3 parts of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio 1:3), 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of super white material B13.

[0063] Secondly, this comparative example also provides a preparation method of a corresponding ceramic dry material, comprising the following steps: In parts by weight, 95 parts of waste glaze for preparing ceramic dry material, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio of 1:3), 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of ultra-white material B13 are stirred and mixed, and the addition of water is properly controlled to prepare the raw material slurry. The slurry is prepared to a water content of 30% and a slurry fineness of 1.25. The prepared slurry is then transported to a spray tower through a Huayan pump for granulation treatment. After being fired at 600°C in the spray tower, honeycomb fine-porous particles are obtained.

[0064] The fine-porous particles are added to a blast frit furnace through a screw feeder and heated at a temperature of 1100°C for 4 minutes for semi-sintering. The temperature is then lowered to 300°C and kept warm for 5 minutes. The blower is then turned off to allow the dry particles to fall freely into a recovery device and pass through a 100-mesh sieve to obtain white particles.

[0065] Subsequently, this comparative example also provides a ceramic tile comprising the ceramic dry material, which comprises, from bottom to top, a brick blank, a glaze layer, a printing layer, and a dry particle layer, wherein the dry particle layer is formed by a dry particle slurry, and the dry particle slurry includes the ceramic dry material; and the preparation method thereof comprises the following steps: The bricks are prepared, glazed after drying, and then printed. After printing, the dry granular slurry made from the ceramic dry material provided in this comparative example is poured on the surface, sent to the kiln, fired at 1220°C, and then polished and graded to obtain ceramic tiles.

[0066] Comparative Example 4 First, this comparative example provides a ceramic dry material, the raw materials of which include 95 parts of waste glaze, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio 1:3), 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of super white material B13.

[0067] Secondly, this comparative example also provides a preparation method of a corresponding ceramic dry material, comprising the following steps: In parts by weight, 95 parts of waste glaze for preparing ceramic dry material, 1 part of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio of 1:3), 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of ultra-white material B13 are stirred and mixed, and the addition of water is properly controlled to prepare the raw material slurry. The slurry is prepared to a water content of 30% and a slurry fineness of 1.0. The prepared slurry is then transported to a spray tower through a Huayan pump for granulation treatment. After being fired at 600°C in the spray tower, honeycomb fine-porous particles are obtained.

[0068] The fine-porous particles were added into a blast frit furnace through a screw feeder and heated at a temperature of 750°C for 4 minutes for semi-sintering. The temperature was then lowered to 300°C and kept warm for 5 minutes. The blower was then turned off to allow the dry particles to fall freely into a recovery device and pass through a 100-mesh sieve to obtain white particles.

[0069] Subsequently, this comparative example also provides a ceramic tile comprising the ceramic dry material, which comprises, from bottom to top, a brick blank, a glaze layer, a printing layer, and a dry particle layer, wherein the dry particle layer is formed by a dry particle slurry, and the dry particle slurry includes the ceramic dry material; and the preparation method thereof comprises the following steps: The bricks are prepared, glazed after drying, and then printed. After printing, the dry granular slurry made from the ceramic dry material provided in this comparative example is poured on the surface, sent to the kiln, fired at 1220°C, and then polished and graded to obtain ceramic tiles.

[0070] Comparative Example 5 First, this comparative example provides a ceramic dry material, the raw materials of which include 95 parts of waste glaze, 5 parts of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio 1:3), 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of super white material B13.

[0071] Secondly, this comparative example also provides a preparation method of a corresponding ceramic dry material, comprising the following steps: In parts by weight, 95 parts of waste glaze for preparing ceramic dry material, 5 parts of inorganic binder (water glass and aluminum dihydrogen phosphate, mass ratio of 1:3), 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of ultra-white material B13 are stirred and mixed, and the addition of water is properly controlled to prepare the raw material slurry. The slurry is prepared to a water content of 30% and a slurry fineness of 10.0. The prepared slurry is then transported to a spray tower through a Huayan pump for granulation treatment. After being fired at 600°C in the spray tower, honeycomb fine-porous particles are obtained.

[0072] The fine-porous particles were added into a blast frit furnace through a screw feeder and heated at a temperature of 870°C for 4 minutes for semi-sintering. The temperature was then lowered to 300°C and kept at this temperature for 5 minutes. The blower was then turned off to allow the dry particles to fall freely into a recovery device and pass through a 100-mesh sieve to obtain white particles.

[0073] Subsequently, this comparative example also provides a ceramic tile comprising the ceramic dry material, which comprises, from bottom to top, a brick blank, a glaze layer, a printing layer, and a dry particle layer, wherein the dry particle layer is formed by a dry particle slurry, and the dry particle slurry includes the ceramic dry material; and the preparation method thereof comprises the following steps: The bricks are prepared, glazed after drying, and then printed. After printing, the dry granular slurry made from the ceramic dry material provided in this comparative example is poured on the surface, sent to the kiln, fired at 1220°C, and then polished and graded to obtain ceramic tiles.

[0074] Comparative Example 6 First, this comparative example provides a ceramic dry material, the raw materials of which include 95 parts of waste glaze, 5 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of super white material B13.

[0075] Secondly, this comparative example also provides a preparation method of a corresponding ceramic dry material, comprising the following steps: In parts by weight, 95 parts of waste glaze for preparing ceramic dry material, 2 parts of hydroxypropyl methylcellulose, 1 part of zirconium silicate and 1 part of ultra-white material B13 are stirred and mixed, and the addition of water is appropriately controlled to prepare the raw material slurry. The slurry is adjusted to a water content of 30% and a slurry fineness of 1.0. The prepared slurry is then transported to a spray tower through a Huayan pump for granulation treatment. After being fired at 600°C in the spray tower, honeycomb fine-porous particles are obtained.

[0076] The fine-porous particles were added into a blast frit furnace through a screw feeder and heated at a temperature of 870°C for 4 minutes for semi-sintering. The temperature was then lowered to 300°C and kept at this temperature for 5 minutes. The blower was then turned off to allow the dry particles to fall freely into a recovery device and pass through a 100-mesh sieve to obtain white particles.

[0077] Subsequently, this comparative example also provides a ceramic tile comprising the ceramic dry material, which comprises, from bottom to top, a brick blank, a glaze layer, a printing layer, and a dry particle layer, wherein the dry particle layer is formed by a dry particle slurry, and the dry particle slurry includes the ceramic dry material; and the preparation method thereof comprises the following steps: The bricks are prepared, glazed after drying, and then printed. After printing, the dry granular slurry made from the ceramic dry material provided in this comparative example is poured on the surface, sent to the kiln, fired at 1220°C, and then polished and graded to obtain ceramic tiles.

[0078] Performance testing and result discussion (1) The stain resistance and anti-slip properties of the ceramic tiles of the above-mentioned embodiments and comparative examples were tested. The stain resistance test was carried out in accordance with GB / T 3810.14-2016 Ceramic Tiles Test Methods Part 14: Determination of Stain Resistance. Specific test items and results are shown in Table 1.

[0079] Table 1 The ceramic tiles obtained from each embodiment and comparative example were tested in accordance with the relevant testing methods provided in the current national recommended standards. It is not difficult to see from the results in Table 1 that the test results of Examples 1-5 are all level 5, that is, "clean the tile surface with running hot water (temperature of 55±5°C) for 5 minutes, and then wipe the tile surface with a wet cloth." This shows that within the scope of the technical solution provided in this application, in most cases the performance of the obtained product is stable and the anti-fouling effect is good; Example 6 showed a slight performance degradation, indicating that its higher content of organic binder caused a slight decrease in anti-fouling performance, but according to the current standard test process, although it cannot pass the standard of "clean the tile surface with running hot water (temperature of 55±5°C) for 5 minutes, and then wipe the tile surface with a wet cloth.", it can still meet the requirements. "Manually scrub the tile surface with an ordinary non-abrasive sponge or cloth in a weak detergent (non-abrasive, pH=6.5~7.5), then rinse with running water and wipe clean with a damp cloth." The standard says that its anti-fouling performance is still relatively outstanding, but it also shows that in the technical solution provided in this application, the proportion of organic binder has a more obvious technical impact on the ceramic dry material provided in this application. After the amount of organic binder added increases to a certain level, the performance will decline. Therefore, special attention should be paid to the amount of organic binder added; at the same time, according to the data obtained in Comparative Examples 1 and 2, it can be proved that excessively high or too low an addition amount outside the range of the organic binder addition amount provided in this application will cause the resulting dry material to be used in ceramic tiles. The stain resistance of the ceramic tiles will decline.

[0080] According to the data in Table 1, combined with Example 2, experiments were conducted without adding zirconium silicate, which shows that zirconium silicate is part of the raw materials in this application, and its addition or non-addition will not have a significant effect on the anti-fouling performance of the technical solution provided by this application.

[0081] According to the data in Table 1, combined with Example 1 and Example 3, different ceramic dry materials were prepared by selecting a variety of colorants, which shows that when different colorants are used in this application, it will not cause a significant impact on the stain resistance of ceramic tiles prepared using the ceramic dry materials provided in this application.

[0082] According to the data in Table 1, combined with Example 1, Example 4, Example 5, Comparative Example 5 and Comparative Example 6, multiple experiments were conducted on the range of the amount of inorganic binder added in this application, calculated by weight, wherein the amount of inorganic binder added in Example 1 is 1 part, and the resulting ceramic tiles have excellent pollution resistance, Example 4 and Example 5 are 0.5 parts and 2 parts respectively. Compared with Example 1, the pollution resistance of the ceramic tiles obtained in Example 4 and Example 5 did not change significantly, while the inorganic binder added in Comparative Example 5 exceeded the range provided in this application, and no inorganic binder was added in Comparative Example 6. The data obtained from Comparative Examples 5 and 6 show that when the amount of inorganic binder added exceeds a certain level, it will have a more significant effect on the partial pollution resistance of the obtained ceramic tiles; when no inorganic binder is added, the effect on the pollution resistance is extremely significant.

[0083] Comparative Examples 3 and 4 respectively adopted technical solutions with sintering temperatures different from those provided in this application. As can be seen from Table 1, compared with Example 1, temperatures lower or higher than the preparation method provided in this application will have a significant impact on the stain resistance of the final ceramic tile product.

[0084] (2) The wear resistance test was carried out in accordance with GB / T 3810.7-2016 Test methods for ceramic tiles Part 7: Determination of surface wear resistance of glazed tiles. The results are shown in Table 2.

[0085] Table 2 According to the data provided in Table 2, combined with Examples 1-6, the ceramic dry materials prepared within the scope of the technical solution provided in the present application, after being used to prepare ceramic tiles, the resulting ceramic tiles have excellent wear resistance in most cases. Only when the addition of the organic binder reaches the highest value of the technical solution provided in the present application, will it cause a slight decrease in wear resistance; combined with Comparative Examples 1-6, it is not difficult to see that the ceramic dry materials prepared outside the scope of the technical solution provided in the present application, after being used to prepare ceramic tiles, the wear resistance of the resulting ceramic tiles showed a particularly obvious and significant decrease, from level 4 at 2100 rpm to level 3 at 1500 rpm.

[0086] The samples obtained from each embodiment and comparative example were subjected to a hand feel test, a glaze slurry dissolution test, and a glaze slurry precipitation test. The specific results are shown in Table 3.

[0087] Table 3 It is not difficult to see from Table 3 that the ceramic dry materials provided by the present application prepared by Examples 1-6 are significantly better than the comparative examples 1-6 prepared by the technical solutions different from the present application in terms of feel; the ceramic dry materials provided by the present application prepared by Examples 1-6 are uniformly suspended in the glaze in the precipitation effect test, which is extremely important for quality control in actual production, and the precipitation effect is significantly better than the comparative examples 1-6 prepared by the technical solutions different from the present application; in the glaze dissolving effect test, Examples 1-6 prepared by the technical solutions provided by the present application are all insoluble in the glaze. In summary, it is shown that the ceramic dry materials prepared by the technical solutions provided by the present application are stable in nature and reliable in performance.

[0088] Combine Figure 1 The actual photo of a ceramic dry material in the embodiment shown is specifically a actual photo of the sample of the ceramic dry material worth of Example 1. It is not difficult to see from the photo that its texture is uniform, the color is relatively uniform, and the particle size distribution is also relatively concentrated, indicating that the quality is relatively stable.

[0089] Combine Figure 2 The actual photo of another ceramic dry material in the embodiment shown specifically includes the ceramic dry material produced by adding different colorants in the embodiment. It is not difficult to see from the photo that the color difference of the dry material of the same color is small, indicating that the quality of the ceramic dry material prepared by adding the same colorant is relatively stable.

[0090] Figure 3 For the tiles prepared in Example 1, Figure 4 The ceramic tile prepared in Example 2 is Figure 3 and Figure 4 It can be seen that the dry particles prepared by the present invention are rich in color, the tiles prepared are rich in color, have a strong three-dimensional sense, and have clear color and texture.

[0091] from Figure 5 It can be seen that the dry granular slurry of the present invention has good suspension performance and is not prone to sedimentation. Figure 6 It can be seen that if too much inorganic binder is added, the particles will have high strength and density, and the dry particles will easily precipitate, which is not conducive to production. Figure 7 It can be seen that the glaze dry particles float on the upper layer of the glaze slurry because too much cellulose is added and the dry particles become too porous during the granulation process, resulting in poor density of the dry particles and easy floating on the glaze surface.

[0092] In summary, the inventors in this application have carried out comprehensive creation in many aspects through comprehensive formula and processing technology, thereby achieving the goal of adjusting the density and structure of the product through the formula while obtaining honeycombed primary particles, and then through a semi-sintering process with a specific blast and a specific temperature, so that the primary particles can float in the frit furnace during the semi-sintering process, and complete the semi-sintering in a short time, thereby achieving the preparation of high-quality ceramic dry materials with a specific density.

[0093] More importantly, the ceramic dry material provided in this application is made from the recycling of waste glaze, which makes this technology not only provide economic value, but also solves the social and environmental value of waste recycling.

[0094] Although the description of the present application has been quite detailed and specifically describes several embodiments, it is not intended to be limited to any of these details or embodiments or any particular embodiment, but should be regarded as providing a broad possible interpretation of these claims by reference to the appended claims in view of the prior art, thereby effectively covering the intended scope of the present application. In addition, the above description of the present application is based on the embodiments foreseeable by the applicant, which is intended to provide a useful description, and those non-substantial changes to the present application that have not yet been foreseen may still represent equivalent changes to the present application.

Claims

1. A ceramic dry material, characterized in that: The raw materials include, by weight, 92-96 parts of waste glaze, 0.5-2 parts of inorganic binder, 2-3 parts of organic binder and 0.5-21.5 parts of colorant; the decomposition temperature of the organic binder is 200-400°C.

2. A ceramic dry material according to claim 1, characterized in that, In parts by weight, the colorant includes at least one of 2-5 parts of ancient black material G40, 0.5-1 parts of light red material D10, 1-3 parts of brown yellow material D30, 1-3 parts of gray material D22, 1-3 parts of phantom gray E26, 0.5-1.5 parts of light yellow material S37, 0.5-2 parts of brown red material D31, and 1-3 parts of super white material B13.

3. A ceramic dry material according to claim 1, characterized in that, In parts by weight, the raw materials also include 1-2 parts of zirconium silicate.

4. A ceramic dry material according to claim 1, characterized in that, The inorganic binder includes water glass and aluminum dihydrogen phosphate.

5. A ceramic dry material according to claim 1, characterized in that, The organic binder is non-ionic cellulose mixed ether.

6. A ceramic dry material according to claim 5, characterized in that: The organic binder is hydroxypropyl methylcellulose.

7. A ceramic dry material according to claim 1, characterized in that: The chemical composition of the ceramic dry material includes, by mass percentage, SiO2: 52.14%-55.12%, Al2O3: 14.64%-18.36%, MgO: 2.35%-4.54%, CaO: 6.11%-8.85%, Na2O: 2.75%-4.75%, K2O: 0.19%-0.59%, BaO: 3.41%-5.52%, ZnO: 4.43%-6.36%, SO3: 1.22%-2.63%, and the remainder is loss on ignition and impurities.

8. A method for preparing a ceramic dry material according to any one of claims 1 to 7, characterized in that: The method comprises the following steps: after uniformly mixing the raw materials, spray granulating at 600-680° C., and then semi-sintering at 850-950° C., wherein the semi-sintering time is 2-6 minutes.

9. The method for preparing a ceramic dry material according to claim 8, characterized in that: The semi-sintering process includes: adding primary particles obtained by spray granulation into a blast kiln, blowing the primary particles into suspension by a blower, and semi-sintering at 850° C.-950° C.

10. A ceramic tile, characterized in that: From bottom to top, it includes a brick layer, a glaze layer, a printing layer and a dry particle layer. The dry particle layer is formed by a dry particle slurry. The dry particle slurry includes the ceramic dry material according to any one of claims 1 to 7.

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