Ceramic tile with concave-convex textures and preparation method thereof

Abstract

The invention belongs to the field of architectural ceramics, and discloses a ceramic tile with concave-convex textures and a preparation method thereof.The ceramic tile with the concave-convex textures comprises a green body layer, a plurality of base layer areas, a plurality of concave areas and a plurality of embossed areas are formed on the green body layer, and each base layer area is formed by a glaze layer and a color pattern layer; the concave area is formed by a digital mold pattern layer, a color pattern layer and a glaze layer, and the embossed area is formed by a glue layer and a dry particle layer; wherein the digital mold pattern layer is formed by digital mold ink, raw materials of the digital mold ink comprise basic glaze, and raw materials of the basic glaze comprise, by weight, 17-20 parts of kaolin, 65-69 parts of wollastonite, 11-13 parts of aluminum oxide and 2-4 parts of dolomite; the glaze layer is formed by cover glaze, and the cover glaze comprises SiO2 and Al2O3 in a molar ratio of (3.6-4.6): 1. Different surface roughness and glossiness and various concave-convex touch and visual difference effects are formed in the preset area of the surface of the product, and the antifouling and wear-resisting properties are good.

Description

Technical Field

[0001] This invention belongs to the field of building ceramics technology, and specifically relates to a ceramic tile with concave and convex textures and its preparation method. Background Technology

[0002] As people's living standards continue to improve, their requirements for home decoration are gradually moving towards personalization. Ceramic tile products with textured surfaces and visual differences are increasingly being used in various decorations.

[0003] Existing methods for preparing ceramic tiles with textured surfaces primarily employ a combination of functional inks and glazes. The resulting ceramic tile products have textured surfaces that are mostly below a single plane, lacking a sense of layering in structure and failing to enhance the overall three-dimensional aesthetics. Furthermore, it is difficult to simultaneously create multiple textured tactile sensations and visual differences. Summary of the Invention

[0004] The present invention aims to improve at least one technical problem in the prior art.

[0005] The first aspect of the present invention provides a ceramic tile with a textured surface, comprising a body layer, on which a plurality of base regions, a plurality of recessed regions and a plurality of raised regions are formed. The recessed regions are recessed downward with the plane of the base region as the base point, and the raised regions are raised upward with the plane of the base region as the base point. The base regions are formed by a glaze layer and a color pattern layer, the recessed regions are formed by a digital mold pattern layer, a color pattern layer and a glaze layer, and the raised regions are formed by an adhesive layer and a dry granule layer. The aforementioned digital mold pattern layer is formed by digital mold ink. The raw materials of the digital mold ink include a base glaze, which, by mass percentage, comprises: SiO2 43%-47%, Al2O3 19%-21%, CaO 32%-35%, and MgO 0.3%-1%. The glaze layer mentioned above is formed by a surface glaze, which includes SiO2 and Al2O3 in a molar ratio of (3.6-4.6):1. The aforementioned dry granule layer is formed from matte dry granules and / or colored dry granules. The colored dry granules are obtained by adding colorants to the matte dry granules. The colorants include one of Fe2O3, Cr2O3, CuO, CoO (Co3O4), CoO·Al2O3, and PbCrO4.

[0006] Among them, the aforementioned basic area accounts for 30%-60%, the aforementioned sunken area accounts for 10%-20%, and the aforementioned raised area accounts for 30%-50%; The depression depth of the aforementioned recessed area is 0.1mm-2mm, and the protrusion height of the aforementioned raised area is 0.1mm-2mm.

[0007] The surface roughness (Ra) of the aforementioned base layer area is 100-150µm, and the gloss is 3-5°; the surface roughness (Ra) of the aforementioned recessed area is 50-70µm, and the gloss is 6-8°; the surface roughness (Ra) of the aforementioned raised area is 20-30µm, and the gloss is 9-11°.

[0008] The ceramic tile with raised and recessed texture provided in this application uses a body layer as a base carrier, on which multiple base areas, recessed areas, and raised areas constitute the core three-dimensional structure. Regarding the key raw material characteristics of each area, firstly, the raw material of the digital mold ink used in the digital mold pattern layer includes a base glaze, which comprises a specific ratio of kaolin, wollastonite, alumina, and dolomite. This allows the high calcium content of the wollastonite to be utilized during the high-temperature firing of the digital mold ink. 2+ With its high charge density, calcium oxide forms strong ionic bonds with the silicon-oxygen tetrahedra in the glaze, restricting the free movement of silicon-oxygen chains and enhancing the cohesive force between melt molecules. This strengthens the surface tension of the digital mold ink. At the same time, calcium oxide has strong high-temperature fluxing properties, which appropriately reduces the viscosity of the glaze melt. This ensures the three-dimensionality of the edges of the recessed areas without running flat, while also adjusting the uniformity of the digital mold ink's spread. In addition, aluminum oxide can improve high-temperature stability, kaolinite enhances adhesion, and dolomite helps to improve the hardness of the glaze surface.

[0009] The molar ratio of SiO2 to Al2O3 in the glaze layer of the base layer is (3.6-4.6):1. This low Si-Al molar ratio not only achieves an extremely low gloss of 3-5°, but also, due to the high aluminum content, results in strong chemical bonds within the glaze layer, hindering low-temperature melting and increasing the initial melting temperature. At high temperatures, this effectively allows for the full formation of the glassy phase network within the glaze, resulting in a denser structure with lower porosity. The specific Si-Al molar ratio of the glaze in this application exhibits strong high-temperature ion diffusion, better interpenetration between the glaze and the body interface, a stronger glaze-body bond, and improved sintering density. Furthermore, due to the high stability of its ionic chemical bonds at higher melting temperatures, the glaze possesses higher viscosity and surface tension, limiting better flow and leveling at high temperatures. This retains more micro-unevenness, forming a micro-uneven structure with Ra of 100-150 μm, resulting in a rougher feel.

[0010] In the dry granule layer of the raised area, the matte dry granules themselves have the characteristics of molten material. During the preparation of dry granules, the raw materials have undergone a series of chemical reactions and decomposition processes such as high-temperature melting. The composition is relatively uniform and the chemical bonds are tightly bound. When fired again at high temperature, it mainly spreads through melting. The melting process is slow and the loss on ignition is low (<0.5%). This characteristic avoids a series of processes such as decomposition, degassing, and polymerization reactions that occur during the firing process of conventional raw material glazes. Therefore, the dry granule layer can be presented more delicately, smoothly and densely. The colored dry granules enrich the color expression of the raised area by adding specific colorants.

[0011] This application utilizes a process of layering digital mold ink and adhesive to position matte dry granules. The digital mold ink (in different shades of gray) peels away the glaze to create various recessed effects, while the positioning adhesive (in different shades of gray) matches the matte dry granules to create various raised effects. Combined with the flat effect of the glaze, this not only creates a textured surface on the ceramic tile, enhancing its visual three-dimensionality, but also, due to the different raw materials and compositions of the three materials, produces varying surface roughness and gloss—the base area feels rough and has a dull gloss, the recessed area feels relatively rough and has a slightly dull gloss, and the raised area feels relatively smooth and has a brighter gloss. This creates various textural effects on the product surface, forming a clear and delicate structure with varying depths of undulation, simulating the crisscrossing grooves of natural rock. The roughness and smoothness blend together, enriching the product details and making the texture more realistic and natural, demonstrating significant advantages in high-end commercial spaces and personalized home decoration.

[0012] In some preferred embodiments, the raw materials of the base glaze, by weight, include: 17-20 parts kaolin, 65-69 parts wollastonite, 11-13 parts alumina, and 2-4 parts dolomite.

[0013] In some preferred embodiments, the surface glaze comprises, by weight percentage: SiO2 49.0%-53.0%, Al2O3 20.0%-22.5%, CaO 3.7%-4.4%, K2O 2.0%-2.5%, Na2O 4.6%-5.5%, BaO 4.3%-5.1%, ZnO 2.6%-3.2%, and ZrO 26.0%-8.0%.

[0014] The raw materials of the above-mentioned glaze, by weight, include: 12-15 parts potassium feldspar, 28-34 parts sodium feldspar, 7-8 parts washed kaolin, 5.5-6.5 parts barium carbonate, 3-4 parts zinc oxide, 5.5-6.5 parts calcined clay, 3-4 parts alumina, 6-7 parts calcite, 12-15 parts nepheline, and 9-11 parts zirconium silicate.

[0015] In some preferred embodiments, the raw materials of the digital mold ink also include organic solvents and functional additives, including dispersants, defoamers and anti-settling agents; the raw materials of the digital mold ink, by weight, include: 30-34 parts of base glaze, 54-60 parts of organic solvent, and 10-12 parts of functional additives.

[0016] In some preferred embodiments, the above-mentioned matte dry granules comprise, by mass percentage: 50.5%-55.0% SiO2, 17.6%-20.0% Al2O3, 7.5%-9.0% CaO, 2.3%-3.0% MgO, 1.8%-2.4% K2O, 3.0%-3.9% Na2O, 7.5%-9.0% BaO, and 3.5%-4.4% ZnO.

[0017] The 3.0%-3.9% sodium oxide enhances melting ability, lowers initial melting temperature and melting temperature, resulting in low viscosity during melting, which facilitates the expulsion of small pores. The more than 7.5% calcium oxide promotes sintering at high temperatures, increases the density of the glass body to enhance anti-fouling performance, and also increases the surface tension of the glass melt. During cooling, it compresses small pores and even incorporates gases into the melt, ensuring surface purity and a smooth feel. The approximately 8% barium oxide accelerates the melting rate of the dry granular layer, adjusts the excessively narrow firing range caused by high calcium, and produces opaque crystallization, forming finer and more uniform crystals to optimize the feel. The approximately 4% zinc oxide reduces the thermal expansion coefficient of the glass phase, helps to eliminate bubbles, and improves thermal stability, chemical stability and refractive index, appropriately increasing gloss. Ultimately, it enables the raised area to achieve a gloss of 9-11° and a low roughness of Ra of 20-30μm.

[0018] In some preferred embodiments, the D97 of the above-mentioned matte dry granules is 239µm-243µm.

[0019] In some preferred embodiments, the mass ratio of matte dry granules to colorant in the above-mentioned color dry granules is 1:(0.01-0.03).

[0020] In some preferred embodiments, a dry granule protective layer is also formed on the aforementioned dry granule layer, the dry granule protective layer being formed from a combination of dry granules and a mixture; The combined dry granules include first dry granules and second dry granules. The first dry granules, by mass percentage, comprise: SiO2 49.5%-54.5%, Al2O3 17.0%-20.0%, CaO 3.3%-4.0%, K2O 3.4%-4.1%, Na2O 2.8%-3.4%, BaO 9.8%-11.0%, ZnO 3.3%-4.1%, and SrO 3.3%-4.0%. The second dry granule comprises, by mass percentage: SiO2 50.5%-56.2%, Al2O3 15.5%-18.0%, CaO 6.3%-7.8%, MgO 2.1%-3.0%, K2O 2.8%-3.8%, Na2O 1.8%-2.6%, ZrO2 0.5%-1.0%, BaO 0.5%-0.8%, ZnO 4.3%-5.5%, and SrO 7.0%-8.6%; The mixture includes a suspending agent and a protective glaze. The protective glaze comprises, by mass percentage: SiO2 45.2%-50.2%, Al2O3 16.0%-18.5%, CaO 7.3%-9.1%, MgO 1.4%-2.0%, K2O 3.8%-4.8%, Na2O 1.2%-1.6%, BaO 6.6%-8.0%, ZnO 6.5%-7.8%, and SrO 2.2%-3.0%.

[0021] In some preferred embodiments, the mass ratio of the combined dry granules and the mixture is 1:(0.9-1.1), the mass ratio of the first dry granules and the second dry granules is 1:(0.9-1.1), and the mass ratio of the suspending agent and the protective glaze is 1:(0.9-1.1).

[0022] In some preferred embodiments, the D97 of the first dry granules is 87µm-92µm; the D97 of the second dry granules is 125µm-129µm; and the D97 of the protective glaze is 20µm-24µm.

[0023] This application aims to further optimize the stability of the dry granule layer in the raised area and the overall surface performance of ceramic tiles. A dry granule protective layer is added to the dry granule layer. This protective layer is composed of a combination of dry granules and a mixture. The combination of dry granules includes first and second dry granules, while the mixture consists of a suspending agent and a protective glaze. Through precise matching and complementary properties of the components, efficient protection of the dry granule layer and an upgrade in product surface performance are achieved. Functionally, the first and second dry granules in the combination provide stable structural support for the protective layer through complementary components, ensuring its high-temperature resistance and matching the melting rate. They also synergistically enhance the surface hardness, thermal stability, and fineness of the protective layer, laying the foundation for subsequent fusion with other layers. The suspending agent in the mixture ensures uniform dispersion of the combined dry granules in the protective glaze, preventing particle agglomeration from affecting the protective layer's effect. The protective glaze, with its suitable glass phase characteristics and low-temperature melting properties, effectively reduces the formation of fine pores and cracks on its surface, and also helps the dry granule protective layer better fuse with the underlying dry granule layer and glaze layer. In terms of application effects, compared with the traditional process of spraying dry granule glaze or protective glaze onto the surface glaze, this dry granule protective layer can more effectively retain and fix the dry granules, reducing the displacement and deviation of the dry granules on the surface of the dry granule layer caused by wind pressure in the kiln. At the same time, the dry granule protective layer is thin in shape, which not only does not cover up the three-dimensional effect of the concave and convex areas, but also can quickly penetrate into the gaps between the dry granule layer and the surface glaze, forming a dense surface bonding layer with the two, thereby improving the transparency and stain resistance of the ceramic tile surface, and further optimizing the surface texture and service life of the product.

[0024] A second aspect of the present invention provides a method for preparing the above-mentioned ceramic tile with a textured surface, wherein the color pattern layer is formed by color ink and the adhesive layer is formed by positioning adhesive, and the preparation method includes the following steps: Digital mold pattern ink is sprayed onto the surface of the body layer, a surface glaze is applied, followed by the sequential spraying of color ink and positioning glue, then the application of matte dry granules and / or color dry granules, and firing to obtain ceramic tiles with raised and recessed textures.

[0025] The printing grayscale of the aforementioned digital mold pattern ink is 20-100. The specific gravity of the aforementioned glaze is 1.46 g / cm³. 3 -1.50g / cm 3 The application rate is 520g / m 2 -535g / m 2 ; The grayscale of the aforementioned positioning adhesive pattern is 30-100.

[0026] The application rate of the aforementioned matte dry granules and / or colored dry granules is 540 g / m³. 2 -560g / m 2 ; In some preferred embodiments, a dry granule protective layer is further formed on the aforementioned dry granule layer. The dry granule protective layer is formed by the aforementioned combined dry granules and the aforementioned mixture, wherein the combined dry granules include first dry granules and second dry granules, and the mixture includes a suspending agent and a protective glaze. The first dry granules, the second dry granules, the suspending agent and the protective glaze are mixed to obtain the dry granule mixed glaze. After the application of matte dry granules and / or colored dry granules is completed, the dry granule mixed glaze is applied. The specific gravity of the aforementioned dry-particle mixed glaze is 1.26 g / cm³. 3 -1.30g / cm 3 The application rate is 200g / m 2 -215g / m 2 .

[0027] The beneficial effects of this invention are as follows: The ceramic tiles with raised and recessed textures produced by this invention utilize the physical dispersion characteristics of digital mold ink to make the recessed areas more natural. Simultaneously, different grayscale settings of the digital mold ink create different repulsive forces on the upper glaze, resulting in recesses of varying depths and widths. Similarly, different grayscale printing of the positioning adhesive in the adhesive layer creates differences in adhesion to matte dry granules (and / or colored dry granules), resulting in raised and recessed areas of varying heights. Therefore, the product surface forms a rich raised and recessed effect from recessed areas, base areas, and raised and recessed areas. Through the superposition of the above processes, different surface roughness and gloss, as well as various tactile and visual differences, are formed in predetermined areas on the surface of the product. It exhibits good stain resistance and wear resistance, and the raised and recessed areas can be of the same color or mixed colors, or any single area can be a different color, increasing aesthetic appeal and meeting consumers' personalized aesthetic needs. Attached Figure Description

[0028] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0029] Figure 1 This is a photograph of the ceramic tile with an uneven texture prepared in Example 1. Figure 2 This is a photograph of the ceramic tile with an uneven texture obtained in Example 4. Figure 3 This is a photograph of the ceramic tile produced in Comparative Example 9. Figure 4 This is a photograph of the ceramic tile produced in Comparative Example 10. Detailed Implementation

[0030] The present invention will be further described below with reference to specific embodiments. It should be understood that these embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. Furthermore, it should be understood that after reading the description of this invention, those skilled in the art can make various alterations or modifications to the invention, and these equivalent forms also fall within the scope defined by the appended claims.

[0031] Example 1 A ceramic tile with a textured surface includes a body layer, on which multiple base areas, multiple recessed areas, and multiple raised areas are formed. The recessed areas are recessed downwards with the plane of the base area as the base point, and the raised areas are raised upwards with the plane of the base area as the base point. The base areas are formed by a glaze layer, the recessed areas are formed by a digital mold pattern layer and a glaze layer, and the raised areas are formed by an adhesive layer and a dry granule layer.

[0032] The digital mold pattern layer is formed by digital mold ink, the raw materials of which, by weight, include: 32 parts base glaze, 57 parts ethyl acetate (organic solvent), 7.5 parts polyacrylamide (dispersant), 2 parts polyether-modified silicone (defoamer), and 1.5 parts aluminate (anti-settling agent). The raw materials of the base glaze, by weight, include: 18.5 parts kaolin, 66.5 parts wollastonite, 12 parts alumina, and 3 parts dolomite. The base glaze, by mass percentage, includes: 45.03% SiO2, 20.06% Al2O3, 33.49% CaO, 0.65% MgO, with the remainder being loss on ignition and impurities.

[0033] Its glaze layer is formed by a surface glaze, which, by weight percentage, comprises: SiO2 51.03%, Al2O3 21.15%, CaO 4.07%, K2O 2.22%, Na2O 5.04%, BaO 4.65%, ZnO 2.87%, ZrO 27.0%, with the remainder being loss on ignition and impurities; the molar ratio of SiO2 to Al2O3 is 4.10:1. The raw materials for the surface glaze, by weight, include: potassium feldspar 13 parts, sodium feldspar 31 parts, washed kaolin 7.5 parts, barium carbonate 6 parts, zinc oxide 3.5 parts, calcined clay 6 parts, alumina 3.5 parts, calcite 6.5 parts, nepheline 13 parts, and zirconium silicate 10 parts. The preparation method of the surface glaze includes the following steps: The raw materials of the above-mentioned surface glaze, water, methylcellulose (thickener), and sodium tripolyphosphate (dispersant) are mixed in a mass ratio of 100:30:0.15:0.35, and the mixture is ball-milled, sieved, and aged to obtain the surface glaze. Its dry granular layer is formed by matte dry granules, which, by mass percentage, include: SiO2 52.41%, Al2O3 18.75%, CaO 8.18%, MgO 2.67%, K2O 2.1%, Na2O 3.4%, BaO 8.3%, ZnO 3.87%, with the remainder being loss on ignition and impurities. The raw materials for the matte dry granules, by weight, include: quartz 34 parts, wollastonite 16 parts, calcined talc 8.5 parts, zinc oxide 4 parts, alumina 19 parts, sodium carbonate 6 parts, barium carbonate 8.5 parts, and potassium nitrate 4 parts. The preparation method of matte dry granules includes the following steps: mixing the above-mentioned raw materials for matte dry granules, calcining and melting them at 1400℃ to obtain a glass melt, cooling the molten glass melt with water-cooled metal rollers, crushing it, and obtaining milky white matte dry granules. The D97 of the matte dry granules is 239µm-243µm.

[0034] The method for preparing this textured ceramic tile includes the following steps: The dried blank layer (moisture content less than 0.3%) is fed into the first inkjet printing equipment, and digital mold ink is printed on the surface of the blank layer. The printing grayscale of the digital mold ink is 20-100. The sample is fed into a glaze spraying device to apply the glaze, which has a specific gravity of 1.48 g / cm³. 3 The application rate was 528 g / m³. 2 ; It is fed into the second inkjet printing equipment, where colored ink is printed to form a color pattern layer; The ink is fed into the third inkjet printing equipment, where positioning adhesive (Foshan Yidajia Precision Ceramics Technology Co., Ltd., positioning adhesive model: CIK-AD1109) is printed at the preset position. The grayscale of the positioning adhesive is 30-100. Feed the product into the dry granule application equipment and apply matte dry granules (application rate: 550g / m³). 2 Then, the excess (i.e., unadheded) matte dry particles are removed by suction. The ceramic bricks are fired in a roller kiln at a maximum temperature of 1180℃ to obtain ceramic bricks with textured surfaces.

[0035] A physical image of the ceramic tile with textured surface obtained in Example 1 is shown below. Figure 1 As shown.

[0036] Example 2 A ceramic tile with a textured surface, which differs from Example 1 in that: 1) The surface glaze, by weight percentage, includes: SiO2 52.28%, Al2O3 19.8%, CaO 4.23%, K2O 2.39%, Na2O 4.74%, BaO 4.89%, ZnO 2.67%, ZrO 27.8%, with the remainder being loss on ignition and impurities; the molar ratio of SiO2 to Al2O3 is 4.49:1; the raw materials of the surface glaze, by weight, include: potassium feldspar 14 parts, sodium feldspar 28 parts, washed kaolin 7 parts, barium carbonate 6.5 parts, zinc oxide 3 parts, calcined clay 6.5 parts, alumina 3 parts, calcite 7 parts, nepheline 14 parts, and zirconium silicate 11 parts; 2) The matte dry granules, by mass percentage, include: SiO2 54.47%, Al2O3 17.8%, CaO 7.63%, MgO 2.91%, K2O 2.22%, Na2O 3.12%, BaO 7.6%, ZnO 4.31%, with the remainder being loss on ignition and impurities; the raw materials for the matte dry granules, by weight, include: quartz 37 parts, wollastonite 14.5 parts, calcined talc 9.5 parts, zinc oxide 4.5 parts, alumina 17 parts, sodium carbonate 5.5 parts, barium carbonate 7.5 parts, and potassium nitrate 4.5 parts; 3) The preset position of the positioning adhesive should be adjusted accordingly depending on the color pattern layer formed by the inkjet printing. Everything else is the same as in Example 1.

[0037] Example 3 A ceramic tile with a textured surface, which differs from Example 1 in that: 1) The surface glaze, by weight percentage, includes: SiO2 49.59%, Al2O3 22.2%, CaO 3.79%, K2O 2.08%, Na2O 5.23%, BaO 4.41%, ZnO 3.01%, ZrO2 6.28%, with the remainder being loss on ignition and impurities; the molar ratio of SiO2 to Al2O3 is 3.80:1; the raw materials of the surface glaze, by weight, include: potassium feldspar 12 parts, sodium feldspar 34 parts, washed kaolin 8 parts, barium carbonate 5.5 parts, zinc oxide 4 parts, calcined clay 5.5 parts, alumina 4 parts, calcite 6 parts, nepheline 12 parts, and zirconium silicate 9 parts; 2) The matte dry granules, by weight percentage, include: SiO2 50.78%, Al2O3 19.6%, CaO 8.79%, MgO 2.43%, K2O 1.9%, Na2O 3.82%, BaO 8.7%, ZnO 3.63%, with the remainder being loss on ignition and impurities; the raw materials for the matte dry granules, by weight, include: quartz 31 parts, wollastonite 17.5 parts, calcined talc 7.5 parts, zinc oxide 3.5 parts, alumina 21 parts, sodium carbonate 6.5 parts, barium carbonate 9.5 parts, and potassium nitrate 3.5 parts; 3) The preset position of the positioning adhesive should be adjusted accordingly depending on the color pattern layer formed by the inkjet printing. Everything else is the same as in Example 1.

[0038] Example 4 A ceramic tile with a textured surface, which differs from Example 1 in that: 1) The dry granule layer is formed by colored dry granules, which are obtained by adding Fe2O3 (colorant) to matte dry granules. The mass ratio of matte dry granules to Fe2O3 is 1:0.01, and the colored dry granules are light reddish-brown. 2) In the preparation method, colored dry granules are applied after being fed into the dry granule application equipment; 3) The preset position of the positioning adhesive should be adjusted accordingly depending on the color pattern layer formed by the inkjet printing. Everything else is the same as in Example 1.

[0039] An actual image of the ceramic tile with textured surface obtained in Example 4 is shown below. Figure 2 As shown.

[0040] Example 5 A ceramic tile with a textured surface, which differs from Example 1 in that: 1) A dry granule protective layer is also formed on the dry granule layer. The dry granule protective layer is formed by a combination of dry granules and a mixture in a mass ratio of 1:1. The combination of dry granules includes first dry granules and second dry granules in a mass ratio of 1:1. The first dry granules, by mass percentage, include: SiO2 52.1%, Al2O3 18.56%, CaO 3.6%, K2O 3.72%, Na2O 3.11%, BaO 10.34%, ZnO 3.67%, SrO 3.68%, with the remainder being loss on ignition and impurities. The D97 of the first dry granules is 87µm-92µm. The second dry granule, by mass percentage, comprises: SiO2 53.43%, Al2O3 16.81%, CaO 7.1%, MgO 2.5%, K2O 3.23%, Na2O 2.18%, ZrO2 0.73%, BaO 0.63%, ZnO 4.96%, SrO 7.75%, with the remainder being loss on ignition and impurities; the D97 of the second dry granule is 125µm-129µm. The mixture comprises a suspending agent (Foshan Sanshui Taiyang New Material Co., Ltd., suspending agent model: F310) and a protective glaze in a 1:1 mass ratio. The protective glaze, by mass percentage, comprises: SiO2 47.64%, Al2O3 17.2%, CaO 8.2%, MgO 1.68%, K2O 4.19%, Na2O 1.41%, BaO 7.27%, ZnO 7.13%, SrO 2.55%, with the remainder being loss on ignition and impurities; the protective glaze has a D97 of 20µm-24µm. 2) In the preparation method, the first dry granules, the second dry granules, the suspending agent, and the protective glaze are mixed to obtain a dry granule mixed glaze. After the matte dry granules are applied, the dry granule mixed glaze is applied. The specific gravity of the dry granule mixed glaze is 1.28 g / cm³. 3 The application rate is 207 g / m 2 ; 3) The preset position of the positioning adhesive should be adjusted accordingly depending on the color pattern layer formed by the inkjet printing. Everything else is the same as in Example 1.

[0041] Comparative Example 1 A ceramic tile differs from Example 1 in that: the surface glaze, by weight percentage, comprises: 46.37% SiO2, 23.7% Al2O3, 3.67% CaO, 2.43% K2O, 4.5% Na2O, 4.18% BaO, 3.12% ZnO, 6.4% ZrO2, with the remainder being loss on ignition and impurities; wherein the molar ratio of SiO2 to Al2O3 is 3.32:1; the raw materials of the surface glaze, by weight, comprise: 14 parts potassium feldspar, 28 parts sodium feldspar, 8 parts washed kaolin, 5.5 parts barium carbonate, 4 parts zinc oxide, 6.5 parts calcined clay, 6 parts alumina, 6 parts calcite, 12 parts nepheline, and 10 parts zirconium silicate.

[0042] Everything else is the same as in Example 1.

[0043] Comparative Example 2 A ceramic tile differs from Example 1 in that: the surface glaze, by weight percentage, comprises: 55.2% SiO2, 18.8% Al2O3, 4.27% CaO, 1.8% K2O, 5.45% Na2O, 5.2% BaO, 2.48% ZnO, 6.58% ZrO2, with the remainder being loss on ignition and impurities; wherein the molar ratio of SiO2 to Al2O3 is 4.99:1; the raw materials of the surface glaze, by weight, comprise: 12 parts potassium feldspar, 34 parts sodium feldspar, 7 parts washed kaolin, 6.5 parts barium carbonate, 3 parts zinc oxide, 5.5 parts calcined clay, 1 part alumina, 7 parts calcite, 14 parts nepheline, and 10 parts zirconium silicate.

[0044] Everything else is the same as in Example 1.

[0045] Comparative Example 3 A ceramic tile differs from Example 1 in that: the matte dry granules, by weight percentage, comprise: 52.58% SiO2, 18.83% Al2O3, 8.34% CaO, 2.68% MgO, 2.07% K2O, 1.98% Na2O, 7.12% BaO, 3.98% ZnO, with the remainder being loss on ignition and impurities; the raw materials for the matte dry granules, by weight, comprise: 35 parts quartz, 17 parts wollastonite, 8.5 parts calcined talc, 4 parts zinc oxide, 20 parts alumina, 3 parts sodium carbonate, 8.5 parts barium carbonate, and 4 parts potassium nitrate.

[0046] Everything else is the same as in Example 1.

[0047] Comparative Example 4 A ceramic tile differs from Example 1 in that: the matte dry granules, by weight percentage, comprise: 51.83% SiO2, 18.16% Al2O3, 8.08% CaO, 2.56% MgO, 2.01% K2O, 5.02% Na2O, 7.03% BaO, 3.87% ZnO, with the remainder being loss on ignition and impurities; the raw materials for the matte dry granules, by weight, comprise: 33 parts quartz, 15 parts wollastonite, 8.5 parts calcined talc, 4 parts zinc oxide, 18 parts alumina, 9 parts sodium carbonate, 8.5 parts barium carbonate, and 4 parts potassium nitrate.

[0048] Everything else is the same as in Example 1.

[0049] Comparative Example 5 A ceramic tile differs from Example 1 in that: the matte dry granules, by weight percentage, comprise: 51.28% SiO2, 18.03% Al2O3, 6.12% CaO, 2.58% MgO, 2.07% K2O, 3.34% Na2O, 10.82% BaO, 3.86% ZnO, with the remainder being loss on ignition and impurities; the raw materials for the matte dry granules, by weight, comprise: 35 parts quartz, 11 parts wollastonite, 9 parts calcined talc, 4 parts zinc oxide, 19 parts alumina, 6 parts sodium carbonate, 12 parts barium carbonate, and 4 parts potassium nitrate.

[0050] Everything else is the same as in Example 1.

[0051] Comparative Example 6 A ceramic tile differs from Example 1 in that: the matte dry granules, by weight percentage, comprise: 52.97% SiO2, 18.6% Al2O3, 10.3% CaO, 2.77% MgO, 2.2% K2O, 3.5% Na2O, 4.89% BaO, 4% ZnO, with the remainder being loss on ignition and impurities; the raw materials for the matte dry granules, by weight, comprise: 33 parts quartz, 21 parts wollastonite, 8 parts calcined talc, 4 parts zinc oxide, 19 parts alumina, 6 parts sodium carbonate, 5 parts barium carbonate, and 4 parts potassium nitrate.

[0052] Everything else is the same as in Example 1.

[0053] Comparative Example 7 A ceramic tile differs from Example 1 in that: the base glaze in the raw materials of the digital mold ink comprises, by weight, 21.5 parts kaolin, 61 parts wollastonite, 13.5 parts alumina, and 4 parts dolomite; the base glaze comprises, by mass percentage, 47.5% SiO2, 21.8% Al2O3, 29% CaO, and 0.86% MgO, with the remainder being loss on ignition and impurities.

[0054] Everything else is the same as in Example 1.

[0055] Comparative Example 8 A ceramic tile differs from Example 1 in that: the base glaze in the raw materials of the digital mold ink comprises, by weight, 15 parts kaolin, 73 parts wollastonite, 10.5 parts alumina, and 1.5 parts dolomite; the base glaze comprises, by mass percentage, 43% SiO2, 18.5% Al2O3, 38% CaO, and 0.35% MgO, with the remainder being loss on ignition and impurities.

[0056] Everything else is the same as in Example 1.

[0057] Comparative Example 9 A ceramic tile differs from Example 1 in that it does not involve digital mold ink printing; the color pattern layer formed by the printed color ink is different, and the preset position of the positioning adhesive is also adjusted accordingly.

[0058] Everything else is the same as in Example 1.

[0059] A picture of the ceramic tile prepared in Comparative Example 9 is shown below. Figure 3 As shown.

[0060] Comparative Example 10 A ceramic tile differs from Example 1 in that it does not involve the spraying of positioning adhesive, nor the application of matte dry granules; and the color pattern layer formed by the spraying of colored ink is different.

[0061] Everything else is the same as in Example 1.

[0062] A photograph of the ceramic tile prepared in Comparative Example 10 is shown below. Figure 4 As shown.

[0063] Performance testing Performance tests were conducted on the products of Examples 1-5 and Comparative Examples 1-10, specifically including surface roughness, gloss and surface quality tests. Surface roughness (Ra) was tested using an ultra-high precision microscope, gloss was tested using a gloss meter, and surface quality was tested using the method in GB / T3810.14-2016. The results of the roughness and gloss tests are shown in Table 1, and the results of the surface quality tests are shown in Table 2.

[0064] Table 1. Results of roughness and gloss tests Table 2 Surface Quality Results As can be seen from the test data in Tables 1 and 2 above, the ceramic tiles with concave and convex textures prepared using the technical solution of this invention, through the superposition of multiple processes, produce various textural effects on the product surface, forming clear and delicate undulations of different depths, simulating the natural rock marks with crisscrossing ravines. Various rough and smooth effects are presented in harmony, making the product details richer, the texture more realistic and natural, and the color, shape, and quality excellent.

[0065] Based on the data from Example 1 and Comparative Examples 1-2, it can be seen that when the alumina content in the glaze is too high, the molar ratio of silicon to aluminum is too small, resulting in a higher firing temperature, which leads to a decrease in gloss and a decrease in density, resulting in poorer stain resistance. When the alumina content in the glaze is too low, the molar ratio of silicon to aluminum is too large, resulting in a lower firing temperature, which leads to premature melting of the glaze and an increase in gloss.

[0066] Based on the data from Example 1 and Comparative Examples 3-4, it can be seen that when the sodium oxide content in the matte dry granules is too low, it cannot effectively reduce the melt viscosity, resulting in the inability of the pores in the dry granule layer to expel air smoothly, and the phenomenon of bubbles is easy to occur; when the sodium oxide content in the matte dry granules is too high, it is easy to increase the thermal expansion coefficient of the dry granule layer, resulting in the brick body being easy to deform. At the same time, due to the low bond strength of sodium-oxygen bonds, excessive sodium will reduce the mechanical strength of the dry granule layer.

[0067] Based on the data from Example 1 and Comparative Examples 5-6, it can be seen that when the calcium oxide content in the matte dry granules is low and the barium oxide content is high, the melt viscosity and surface tension will decrease, resulting in poor three-dimensional layering. When the calcium oxide content in the matte dry granules is high and the barium oxide content is low, the liquid phase melting temperature will increase, resulting in a narrow firing range. It will be difficult to effectively reduce the melt viscosity in the high-temperature range, resulting in poor venting performance.

[0068] Based on the data from Example 1 and Comparative Examples 7-8, it can be seen that when the calcium oxide content in the raw material of digital mold ink is low, the surface tension decreases, resulting in the edges of the recessed area being easy to flatten and having poor three-dimensionality; when the calcium oxide content in the raw material of digital mold ink is high, the surface tension is too high, resulting in the edges of the recessed area being steep and the roughness increasing.

[0069] Based on the data from Example 1 and Comparative Examples 9-10, it can be seen that when digital mold ink is not printed, the recessed effect is lacking, resulting in a monotonous overall layer and a weak visual three-dimensional effect; when positioning adhesive is not printed and matte dry granules are not applied, the lubrication effect is lacking, which also results in a monotonous overall layer and a weak visual three-dimensional effect.

[0070] In the description of this specification, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature.

[0071] The above description is only a preferred embodiment of the present invention. It should be noted that those skilled in the art can make several improvements and additions without departing from the method of the present invention, and these improvements and additions should also be considered within the scope of protection of the present invention.

Claims

1. A ceramic tile with an embossed texture, characterized in that, The material includes a blank layer, on which multiple base areas, multiple recessed areas, and multiple raised areas are formed. The recessed areas are recessed downward with the plane of the base area as the base point, and the raised areas are raised upward with the plane of the base area as the base point. The base area is formed by a glaze layer and a color pattern layer. The recessed areas are formed by a digital mold pattern layer, a color pattern layer, and the glaze layer. The raised areas are formed by an adhesive layer and a dry granule layer. The digital mold pattern layer is formed by digital mold ink, the raw materials of which include a base glaze, which by mass percentage comprises: SiO2 43%-47%, Al2O3 19%-21%, CaO 32%-35%, MgO 0.3%-1%; The glaze layer is formed by a surface glaze, which comprises SiO2 and Al2O3 in a molar ratio of (3.6-4.6):1; The dry granule layer is formed from matte dry granules and / or colored dry granules. The colored dry granules are obtained by adding a colorant to the matte dry granules. The colorant includes one of Fe2O3, Cr2O3, CuO, CoO (Co3O4), CoO·Al2O3, and PbCrO4.

2. The ceramic tile with textured surface according to claim 1, characterized in that, The surface glaze comprises, by weight percentage: SiO2 49.0%-53.0%, Al2O3 20.0%-22.5%, CaO 3.7%-4.4%, K2O 2.0%-2.5%, Na2O 4.6%-5.5%, BaO 4.3%-5.1%, ZnO 2.6%-3.2%, and ZrO2 6.0%-8.0%.

3. The ceramic tile with textured surface according to claim 1, characterized in that, The raw materials of the digital mold ink also include organic solvents and functional additives, including dispersants, defoamers and anti-settling agents; the raw materials of the digital mold ink include, by weight: 30-34 parts of the base glaze, 54-60 parts of the organic solvent and 10-12 parts of the functional additives.

4. The ceramic tile with textured surface according to claim 1, characterized in that, The matte dry granules comprise, by mass percentage: SiO2 50.5%-55.0%, Al2O3 17.6%-20.0%, CaO 7.5%-9.0%, MgO 2.3%-3.0%, K2O 1.8%-2.4%, Na2O 3.0%-3.9%, BaO 7.5%-9.0%, and ZnO 3.5%-4.4%.

5. The ceramic tile with an uneven texture according to claim 1, characterized in that, The mass ratio of the matte dry granules to the colorant in the color dry granules is 1:(0.01-0.03).

6. The ceramic tile with an uneven texture according to claim 1, characterized in that, A dry granule protective layer is also formed on the dry granule layer, the dry granule protective layer being formed by a combination of dry granules and a mixture; The combined dry granules include first dry granules and second dry granules. The first dry granules, by mass percentage, comprise: SiO2 49.5%-54.5%, Al2O3 17.0%-20.0%, CaO 3.3%-4.0%, K2O 3.4%-4.1%, Na2O 2.8%-3.4%, BaO 9.8%-11.0%, ZnO 3.3%-4.1%, and SrO 3.3%-4.0%. The second dry granules, by mass percentage, comprise: SiO2 50.5%-56.2%, Al2O3 15.5%-18.0%, CaO 6.3%-7.8%, MgO 2.1%-3.0%, K2O 2.8%-3.8%, Na2O 1.8%-2.6%, ZrO2 0.5%-1.0%, BaO 0.5%-0.8%, ZnO 4.3%-5.5%, and SrO 7.0%-8.6%. The mixture comprises a suspending agent and a protective glaze, wherein the protective glaze comprises, by mass percentage: SiO2 45.2%-50.2%, Al2O3 16.0%-18.5%, CaO 7.3%-9.1%, MgO 1.4%-2.0%, K2O 3.8%-4.8%, Na2O 1.2%-1.6%, BaO 6.6%-8.0%, ZnO 6.5%-7.8%, and SrO 2.2%-3.0%.

7. The ceramic tile with an uneven texture according to claim 6, characterized in that, The mass ratio of the combined dry granules to the mixture is 1:(0.9-1.1), the mass ratio of the first dry granules to the second dry granules is 1:(0.9-1.1), and the mass ratio of the suspending agent to the protective glaze is 1:(0.9-1.1).

8. A method for preparing a ceramic tile with an uneven texture as described in any one of claims 1-5, characterized in that, The color pattern layer is formed by color ink, the adhesive layer is formed by positioning adhesive, and the preparation method includes the following steps: The digital mold pattern ink is sprayed onto the surface of the body layer, the surface glaze is applied, and then the color ink and the positioning adhesive are sprayed in sequence. Then the matte dry granules and / or color dry granules are applied, and the ceramic tile with the textured surface is obtained.

9. The method for preparing ceramic tiles with textured surfaces according to claim 8, characterized in that, The printing grayscale of the digital mold pattern ink is 20-100; And / or, the specific gravity of the glaze is 1.46 g / cm³. 3 -1.50g / cm 3 The amount of the surface glaze applied is 520 g / m. 2 -535g / m 2 ; And / or, the grayscale of the inkjet printing of the positioning adhesive pattern is 30-100; And / or, the application rate of the matte dry granules and / or the colored dry granules is 540 g / m³. 2 -560g / m 2 .

10. The method for preparing ceramic tiles with textured surfaces according to claim 8, characterized in that, A dry granule protective layer is also formed on the dry granule layer, the dry granule protective layer being formed from a combination of dry granules and a mixture in a mass ratio of 1:(0.9-1.1); The combined dry granules include a first dry granule and a second dry granule in a mass ratio of 1:(0.9-1.1). The first dry granule comprises, by mass percentage: SiO2 49.5%-54.5%, Al2O3 17.0%-20.0%, CaO 3.3%-4.0%, K2O 3.4%-4.1%, Na2O 2.8%-3.4%, BaO 9.8%-11.0%, ZnO 3.3%-4.1%, and SrO 3.3%-4.0%. The second dry granules, by mass percentage, comprise: SiO2 50.5%-56.2%, Al2O3 15.5%-18.0%, CaO 6.3%-7.8%, MgO 2.1%-3.0%, K2O 2.8%-3.8%, Na2O 1.8%-2.6%, ZrO2 0.5%-1.0%, BaO 0.5%-0.8%, ZnO 4.3%-5.5%, and SrO 7.0%-8.6%. The mixture comprises a suspending agent and a protective glaze in a mass ratio of 1:(0.9-1.1), wherein the protective glaze comprises, by mass percentage: SiO2 45.2%-50.2%, Al2O3 16.0%-18.5%, CaO 7.3%-9.1%, MgO 1.4%-2.0%, K2O 3.8%-4.8%, Na2O 1.2%-1.6%, BaO 6.6%-8.0%, ZnO 6.5%-7.8%, and SrO 2.2%-3.0%; The first dry granules, the second dry granules, the suspending agent, and the protective glaze are mixed to obtain a dry granule mixed glaze. After the application of the matte dry granules and / or colored dry granules is completed, the dry granule mixed glaze is applied. The specific gravity of the dry-granule mixed glaze is 1.26 g / cm³. 3 -1.30g / cm 3 The application amount of the dry granule mixed glaze is 200 g / m³. 2 -215g / m 2 .

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