Preparation process of pearl effect ceramic tile

Abstract

The application discloses a preparation process of pearlescent effect ceramic tiles, and relates to the technical field of ceramic tile production. The process comprises the steps of body preparation and forming, drying and decoration, surface glazing, pearlescent dry particle glazing, firing and polishing, and inspection. The innovation lies in that when the surface glazing layer is in a wet state, the pearlescent dry particle glazing with a particle size of 80-150 mesh is uniformly scattered on the glazing surface, and then the dry particle is firmly combined with the glazing surface by firing at 1190-1210 DEG C in an oxidizing atmosphere. In order to realize uniform scattering, a special scattering mechanism is designed. The infrared induction controls the quantitative feeding and discharging of the rotating cylinder, and the dry particles are dispersed and fall by means of the vibrating frame and the screen. The method effectively solves the problems of uneven distribution and poor adhesion of the pearlescent layer, and the prepared ceramic tile has uniform and soft pearlescent effect, and the stain resistance, wear resistance and adhesion strength are significantly improved. The process is stable and suitable for industrial production.

Description

Technical Field

[0001] This invention relates to the field of ceramic tile production technology, specifically a preparation process for pearlescent ceramic tiles. Background Technology

[0002] Tiles, as an indispensable material in the construction and decoration fields, have undergone a significant leap in development, from fulfilling basic paving functions to pursuing high-end decorative aesthetics. Traditional tiles mainly achieve color and basic texture through coloring the body or applying colored glazes to the surface. With the upgrading of consumption and the strong market demand for vivid and personalized expression of spatial aesthetics, tile products with special visual and tactile effects have emerged. Among them, pearlescent tiles are highly favored for their unique surface texture.

[0003] Pearlescent effect tiles refer to tiles that exhibit a soft, warm, and visually changing optical effect on their surface, similar to natural pearls, mother-of-pearl, or certain metal oxides. This effect does not result from strong specular reflection but is based on the combined effects of interference, diffraction, and diffuse reflection of light at the microscopic level. The key to achieving this effect is typically the introduction of pearlescent materials with special optical structures into the tile glaze. The most common method is to use pearlescent pigments made from mica sheets coated with a thin film of high-refractive-index metal oxides such as titanium dioxide. These pigments exist in dry granule form and must be embedded into the tile glaze through a specific process.

[0004] The common process for producing pearlescent ceramic tiles using existing technology involves applying a base glaze or top glaze to a pre-formed tile blank, then sprinkling a layer of pearlescent dry granules on the surface, and finally firing at high temperature to melt the glaze and fix the pearlescent dry granules within it. However, this seemingly straightforward process faces unresolved technical bottlenecks in actual large-scale, high-quality production.

[0005] First, controlling the uniformity of pearlescent dry granules distribution on the glaze surface is difficult. The fine particle size of pearlescent dry granules makes them prone to static electricity and agglomeration, and their flowability is significantly affected by environmental humidity and particle shape. Existing spreading equipment, such as simple vibrating screens or fixed feeding devices, struggles to achieve precise and uniform coverage of the dry granules on the surface of moving tile blanks, especially on glazes with pre-printed complex textures or patterns. Uneven spreading leads to noticeable differences in light and dark areas, color spots, or streaks on the tile surface after firing. The pearlescent effect appears as an unpleasant "cloud-like" or "tear-like" distribution, severely damaging the overall decorative integrity and aesthetics, directly resulting in a reduction in product grade or even scrapping.

[0006] Secondly, there are issues with the bonding strength between the pearlescent granules and the glaze. Current processes often lack precise control over the timing of application. If the granules are applied after the glaze layer has completely dried and hardened, the two are merely physically stacked, lacking initial adhesion. During subsequent firing, because the granules are not in close contact with the underlying dry glaze, the glaze's wetting and encapsulation are often insufficient, resulting in a weak interface. The direct consequence of this weak bonding is poor adhesion of the pearlescent layer. Under subsequent edge grinding, polishing, or long-term cleaning and friction during use, the pearlescent granules are easily detached, forming localized, dull "bald spots." This not only completely negates the decorative effect but also disrupts the continuity and density of the glaze, leading to a series of derivative quality problems such as reduced stain resistance, decreased wear resistance, and increased susceptibility to bacteria, significantly shortening the product's effective lifespan.

[0007] Furthermore, the quality of the pearlescent effect is not determined by a single parameter, but is influenced by a complex interplay of factors, including the adaptability of the body and glaze, the viscosity and drying speed of the glaze, the physicochemical properties of the dry granules, the amount applied, the humidity of the glaze surface during application, the firing temperature profile, and the kiln atmosphere. Current technologies lack systematic research and collaborative optimization schemes for these key process nodes and their interrelationships, resulting in a narrow production process window and high parameter sensitivity. Any minor fluctuations during production can be amplified, causing significant differences in the pearlescent effect and physical properties between different batches, and even between products from the same batch. This makes it difficult to consistently improve the yield of high-quality products, leading to high production costs and hindering the large-scale promotion and application of this type of ceramic tile.

[0008] Therefore, there is an urgent need for an innovative preparation process that can fundamentally guarantee a highly uniform distribution of pearlescent dry particles on the ceramic tile glaze and an extremely strong chemical-physical bond, while also possessing good process stability and a wide operating window to meet the stringent requirements of modern industrial production lines for efficiency, quality, and consistency. Summary of the Invention

[0009] The purpose of this invention is to provide a preparation process for pearlescent ceramic tiles. This process, through optimized body and glaze formulations, key process parameters, and specific glazing and firing steps, can stably produce high-quality ceramic tiles with uniform pearlescent effect and soft luster, thereby solving the problems of uneven distribution of pearlescent dry particles, poor adhesion to the glaze surface, and poor process stability in existing ceramic tiles.

[0010] To achieve the above objectives, the present invention provides the following technical solution: a preparation process for pearlescent effect ceramic tiles, characterized by the following specific steps:

[0011] Step 1, Green Body Preparation and Forming: After weighing the raw materials for the green body according to the proportion, they are put into a ball mill for wet ball milling to make a slurry. The slurry is then dried in a spray drying tower to make granular powder, and then pressed into brick blanks by a fully automatic hydraulic press.

[0012] Step 2, Drying and Decoration: The brick blanks are sent into a drying kiln for drying. After drying, decorative patterns are printed on the surface of the brick blanks.

[0013] Step 3: Apply surface glaze: Apply a layer of moist surface glaze evenly to the surface of the brick blank after printing the pattern;

[0014] Step 4: Apply pearlescent dry granule glaze: While the surface glaze is still wet, evenly sprinkle the pearlescent dry granule glaze onto the wet glaze surface;

[0015] Step 5, Firing: The glazed brick blanks are sent into a roller kiln for firing, so that the surface glaze melts and combines with the pearlescent dry particles to form a glaze surface with a pearlescent effect.

[0016] Step Six: Polishing, Inspection and Packaging: After firing, the tiles are cooled, polished, and inspected before being stored in the warehouse.

[0017] Preferably, in step one, the raw materials for the green body, based on the total mass of the raw materials, include the following components: clay: 45-55 parts; quartz: 25-35 parts; feldspar: 15-25 parts; kaolin: 5-15 parts.

[0018] Preferably, in step three, the glaze application amount is 450-470 g / m².

[0019] Preferably, in step four, the amount of pearlescent dry granule glaze applied is 90-110 g / m².

[0020] Preferably, in step four, the pearlescent dry granule glaze comprises a base glaze and a pearlescent effect material; the base glaze is a low-temperature transparent frit glaze, comprising, by mass, 30-40 parts silica sand, 20-30 parts borax, 10-15 parts soda ash, 5-10 parts zinc oxide, and 5-8 parts calcium carbonate; the pearlescent effect material is a mica-based pearlescent pigment, the amount of which is added is 5-15% of the total mass of the base glaze; the particle size of the pearlescent dry granule glaze is 80-150 mesh.

[0021] Preferably, in step five, the firing is carried out in an oxidizing atmosphere, the maximum firing temperature is 1190-1210℃, and the total firing cycle is 50-70 minutes.

[0022] As a further embodiment of the present invention, the application of pearlescent dry granule glaze in step four is carried out using a pearlescent dry granule glaze applicator. The applicator includes a first conveyor belt and a second conveyor belt, with the second conveyor belt positioned above the first conveyor belt. The first conveyor belt is used to transport the ceramic tile, and the second conveyor belt is used to transport the pearlescent dry granule glaze. The pearlescent dry granule glaze is applied to the ceramic tile via an applicator, and an anti-sticking mechanism prevents clumping or blockage. The applicator includes an infrared transmitter and an infrared receiver, which are respectively installed on both sides of the first conveyor belt. A base is provided below the first conveyor belt, and supports are symmetrically fixed to the top of the base. A support base is provided, with a spring fixedly connected to its top end, a connecting plate fixedly connected to the top end of the spring, a vibrating frame fixedly connected between the two connecting plates, a screen fixedly connected to the bottom end of the inner wall of the vibrating frame, a limit hole formed on the outer wall of the connecting plate, a limit post fixedly connected to the top end of the support base inside the spring, the limit post passing through the limit hole, a support frame fixedly connected to the top end of the base on one side of the support base, a hopper fixedly connected to the top end of the support frame, a discharge port fixedly connected to the bottom end of the hopper, a motor mounted on one side of the support frame, a connecting shaft connected to the output end of the motor, a rotating disk fixedly connected to one end of the connecting shaft, and a protrusion fixedly connected to the outer wall of the rotating disk.

[0023] As a further embodiment of the present invention: the spreading mechanism further includes a first spur gear, which is fixedly connected to the outer wall of the connecting shaft. A hydraulic cylinder is installed at the top of the inner wall of the support frame. The output end of the hydraulic cylinder is connected to a displacement frame, which is slidably connected to the support frame. A fixed seat is fixedly connected to the inner wall of the support frame on one side of the hydraulic cylinder. A second spur gear is rotatably connected to one side of the displacement frame. A first bevel gear is fixedly connected to one end of the second spur gear. The first bevel gear is rotatably connected to the interior of the displacement frame. A second bevel gear is rotatably connected to the interior of the displacement frame on the outer wall of the first bevel gear. A square telescopic rod is fixedly connected to the top of the second bevel gear. A third bevel gear is fixedly connected to the top of the square telescopic rod. The third bevel gear is rotatably connected to the interior of the fixed seat. A fourth bevel gear is rotatably connected to the interior of the fixed seat on the outer wall of the third bevel gear. A rotating cylinder is fixedly connected to one end of the fourth bevel gear. The rotating cylinder is rotatably connected to the interior of the discharge port. A groove is formed on the outer wall of the rotating cylinder.

[0024] As a further embodiment of the present invention: the anti-sticking mechanism includes an agitating roller, which is rotatably connected to the inner cavity of the hopper. A third spur gear is fixedly connected to one end of the agitating roller, and a fourth spur gear is fixedly connected to one end of the rotating cylinder. The third spur gear is in contact with the fourth spur gear. A fixing frame is fixedly connected to the outer wall of the discharge port. A first arc-shaped plate and a second arc-shaped plate are fixedly connected to the outer wall of the fixing frame. The second arc-shaped plate is located above the first arc-shaped plate. A movable plate is slidably connected inside the rotating cylinder. A partition plate extending to the inner wall of the groove is fixedly connected to the top of the movable plate. A threaded rod penetrating the movable plate is rotatably connected inside the rotating cylinder. A fifth bevel gear is fixedly connected to the bottom end of the threaded rod. A sixth bevel gear is rotatably connected to the outer wall of the fifth bevel gear inside the rotating cylinder. A fifth spur gear is fixedly connected to one end of the sixth bevel gear.

[0025] As a further embodiment of the present invention: the inner wall diameter of the limiting hole is larger than the outer wall diameter of the limiting post; the first spur gear meshes with the second spur gear, the first bevel gear meshes with the second bevel gear; and the third bevel gear meshes with the fourth bevel gear.

[0026] As a further embodiment of the present invention: the fourth spur gear meshes with the third spur gear; the inner side of the first arc-shaped plate and the outer wall of the second arc-shaped plate are both provided with tooth grooves, and the tooth grooves mesh with the fifth spur gear.

[0027] As a further embodiment of the present invention: the sixth bevel gear meshes with the fifth bevel gear, and the outer wall of the movable plate is provided with a threaded hole, which matches the threaded rod.

[0028] Compared with the prior art, the beneficial effects of the present invention are:

[0029] 1. The pearlescent effect ceramic tile manufacturing process of this invention creatively limits the application of the pearlescent particles to a specific moist window period before the surface glaze has dried, allowing the pearlescent particles to be partially embedded and trapped within the wet glaze. This step, combined with a specific high-temperature oxidation firing regime, ensures that the surface glaze fully melts during subsequent firing, forming a strong chemical bond and physical encapsulation with the pearlescent particles, rather than simply physical accumulation. This effectively prevents particle agglomeration, achieving macroscopic uniformity and microscopic layering of the pearlescent effect, with gloss levels stably controlled within the comfortable visual range of 35-38 GU.

[0030] 2. The pearlescent effect ceramic tile prepared by this invention has a denser and more complete glaze surface due to the strong bond and uniform distribution of the pearlescent dry particles to the glaze surface. It has good anti-fouling properties and high surface wear resistance, which meets the requirements of high-end ceramic tiles for easy cleaning and durability.

[0031] 3. This invention improves the design of the pearlescent dry granule glaze spreader. The motor drives the connecting shaft to rotate, and the protrusions displace and impact the connecting plate, causing the connecting plate and the vibrating frame to vibrate. When the ceramic tile passes the infrared emitter, the displacement frame moves downwards, and the first spur gear contacts the second spur gear. At this time, the rotation of the first spur gear drives the rotating cylinder to rotate. When the groove faces upwards, the pearlescent dry granule glaze in the hopper falls into the groove. When the groove faces downwards, the pearlescent dry granule glaze in the groove falls along the discharge port into the fourth bevel gear. The vibration of the fourth bevel gear causes the pearlescent dry granule glaze to evenly pass through the screen and fall onto the ceramic tile, facilitating the even spreading of the pearlescent dry granule glaze onto the ceramic tile.

[0032] 4. The pearlescent dry granule glaze spreader is equipped with an anti-sticking mechanism. When the rotating drum rotates, the agitating roller also rotates, stirring the pearlescent dry granule glaze in the hopper to prevent clumping or blockage. The pearlescent dry granule glaze enters the groove, and then the rotating drum rotates, driving the fifth spur gear to move. The fifth spur gear contacts the first arc-shaped plate, and its rotation causes the partition plate to move into the groove, cutting the pearlescent dry granule glaze in the groove, thus further preventing clumping. Then, the fifth spur gear contacts the second arc-shaped plate, and the partition plate moves out of the groove, further preventing the pearlescent dry granule glaze from clumping or blocking in the hopper. Attached Figure Description

[0033] Figure 1 This is a schematic diagram of the structure of the pearlescent dry granule glaze spreading machine described in this invention;

[0034] Figure 2 This is a schematic diagram of the base of the pearlescent dry granule glaze applicator described in this invention;

[0035] Figure 3 This is a schematic diagram of the support base of the pearlescent dry granule glaze applicator described in this invention;

[0036] Figure 4 This is a schematic diagram of the installation of the screen of the pearlescent dry granule glaze spreader described in this invention;

[0037] Figure 5 This is a schematic diagram of the internal structure of the support frame of the pearlescent dry granule glaze applicator described in this invention;

[0038] Figure 6 This is a schematic diagram of the internal structure of the displacement frame of the pearlescent dry granule glaze spreading machine described in this invention;

[0039] Figure 7 This is a schematic diagram of the internal structure of the hopper of the pearlescent dry granule glaze spreader described in this invention;

[0040] Figure 8 This is a schematic diagram of the installation of the third and fourth spur gears of the pearlescent dry granule glaze spreader described in this invention;

[0041] Figure 9 This is a schematic diagram of the structure of the first and second arc-shaped plates of the pearlescent dry granule glaze spreading machine of the present invention;

[0042] Figure 10 This is a schematic diagram of the internal structure of the rotating cylinder of the pearlescent dry granule glaze spreading machine described in this invention.

[0043] In the diagram: 1. First conveyor belt; 2. Second conveyor belt; 3. Spreading mechanism; 301. Infrared transmitter; 302. Infrared receiver; 303. Base; 304. Support seat; 305. Spring; 306. Connecting plate; 307. Vibrating frame; 308. Screen; 309. Limiting hole; 310. Limiting post; 311. Support frame; 312. Hopper; 313. Discharge port; 314. Motor; 315. Connecting shaft; 316. Rotary disc; 317. Protrusion; 318. First spur gear; 319. Hydraulic cylinder; 320. Displacement frame; 321. Fixing element. 322. Seat; 323. Second spur gear; 324. First bevel gear; 325. Second bevel gear; 326. Square telescopic rod; 327. Third bevel gear; 328. Fourth bevel gear; 329. Rotating cylinder; 4. Groove; 4. Anti-sticking mechanism; 401. Agitating roller; 402. Third spur gear; 403. Fourth spur gear; 404. Fixing frame; 405. First arc-shaped plate; 406. Second arc-shaped plate; 407. Divider plate; 408. Movable plate; 409. Threaded rod; 410. Fifth bevel gear; 411. Sixth bevel gear; 412. Fifth spur gear. Detailed Implementation

[0044] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0045] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance. In the description of this invention, it should be noted that unless otherwise explicitly specified and limited, the terms "installed," "connected," "linked," and "set up" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. The following describes embodiments of the invention based on its overall structure. Example 1

[0046] This embodiment provides a manufacturing process for pearlescent ceramic tiles, the specific steps of which are as follows:

[0047] Step 1: Preparation and Molding of the Green Body: Select the following raw materials by weight, based on the total weight of the raw materials: 45 parts clay, 35 parts quartz, 15 parts feldspar, and 5 parts kaolin. Put the raw materials into a ball mill for wet ball milling to make a slurry. After spray drying to produce powder, press the slurry using a fully automatic hydraulic press to obtain the brick blank.

[0048] Step 2, Drying and Decoration: After the brick blanks are dried in a drying kiln, a preset stone pattern is printed on their surface using a high-definition digital inkjet printer.

[0049] Step 3: Apply surface glaze: Use a high-precision bell-shaped glaze spraying machine to evenly apply surface glaze to the surface of the brick body with the printed pattern. The amount of glaze applied should be controlled at 450 g / ㎡ to form a moist glaze layer.

[0050] Step 4: Apply pearlescent dry granule glaze: While the surface glaze is still moist (within 60 seconds after application), evenly spread the pearlescent dry granule glaze onto the glaze surface using a pearlescent dry granule glaze spreader. The spreading amount is 90 g / ㎡. The pearlescent dry granule glaze, by weight, consists of the following components: a base glaze (30 parts silica sand, 30 parts borax, 10 parts soda ash, 10 parts zinc oxide, 5 parts calcium carbonate) mixed with 5% (by weight of the base glaze) titanium mica pearlescent pigment, with a particle size of 150 mesh.

[0051] Step 5: Firing: The glazed brick blanks are fed into a fully automatic wide-body roller kiln and fired in an oxidizing atmosphere. The firing regime is as follows: firing at the highest temperature of 1190℃ for a total firing cycle of 70 minutes.

[0052] Step Six: Polishing, Inspection and Packaging: After firing, the tiles are gently polished after cooling, and after passing inspection, they are packaged and stored.

[0053] Please refer to this carefully. Figures 1 to 7 In step four, the pearlescent dry granule glaze is applied using a pearlescent dry granule glaze applicator. The pearlescent dry granule glaze applicator includes a first conveyor belt 1 and a second conveyor belt 2. The second conveyor belt 2 is positioned above the first conveyor belt 1. The first conveyor belt 1 is used to transport the ceramic tile, and the second conveyor belt 2 is used to transport the pearlescent dry granule glaze. The pearlescent dry granule glaze is applied to the ceramic tile by an applicator 3, and the pearlescent dry granule glaze is prevented from clumping or blocking by an anti-sticking mechanism 4.

[0054] The spreading mechanism 3 includes an infrared transmitter 301 and an infrared receiver 302, which are respectively installed on both sides of the first conveyor belt 1. A base 303 is provided below the first conveyor belt 1. A support seat 304 is symmetrically fixedly connected to the top of the base 303. A spring 305 is fixedly connected to the top of the support seat 304. A connecting plate 306 is fixedly connected to the top of the spring 305. A vibrating frame 307 is fixedly connected between the two connecting plates 306. A screen 308 is fixedly connected to the bottom of the inner wall of the vibrating frame 307. A limit switch is provided on the outer wall of the connecting plate 306. Hole 309, the top of support base 304 is fixedly connected to limit post 310 inside spring 305, limit post 310 passes through limit hole 309, the top of base 303 is fixedly connected to support frame 311 on one side of support base 304, the top of support frame 311 is fixedly connected to hopper 312, the bottom of hopper 312 is fixedly connected to discharge port 313, motor 314 is installed on one side of support frame 311, the output end of motor 314 is connected to connecting shaft 315, one end of connecting shaft 315 is fixedly connected to rotating disk 316, the outer wall of rotating disk 316 is fixedly connected to protrusion 317.

[0055] The spreading mechanism 3 also includes a first spur gear 318, which is fixedly connected to the outer wall of the connecting shaft 315. A hydraulic cylinder 319 is installed at the top of the inner wall of the support frame 311. The output end of the hydraulic cylinder 319 is connected to a displacement frame 320, which is slidably connected to the support frame 311. A fixed seat 321 is fixedly connected to the inner wall of the support frame 311 on one side of the hydraulic cylinder 319. A second spur gear 322 is rotatably connected to one side of the displacement frame 320. A first bevel gear 323 is fixedly connected to one end of the second spur gear 322 and rotatably connected inside the displacement frame 320. Inside the frame 320, a second bevel gear 324 is rotatably connected to the outer wall of the first bevel gear 323. A square telescopic rod 325 is fixedly connected to the top of the second bevel gear 324. A third bevel gear 326 is fixedly connected to the top of the square telescopic rod 325. The third bevel gear 326 is rotatably connected to the inside of the fixed base 321. Inside the fixed base 321, a fourth bevel gear 327 is rotatably connected to the outer wall of the third bevel gear 326. A rotating cylinder 328 is fixedly connected to one end of the fourth bevel gear 327. The rotating cylinder 328 is rotatably connected to the inside of the discharge port 313. A groove 329 is provided on the outer wall of the rotating cylinder 328.

[0056] In this embodiment: Pearlescent dry granule glaze is conveyed to the hopper 312 for collection via the second conveyor belt 2, while the first conveyor belt 1 conveys the ceramic tiles coated with the glaze layer; the motor 314 drives the connecting shaft 315 to rotate, which in turn drives the rotating disk 316 to rotate, which in turn drives the protrusion 317 to move circumferentially, causing the protrusion 317 to collide with the connecting plate 306, thus causing the connecting plate 306 and the vibration frame 307 to vibrate; when the ceramic tile passes the infrared emitter 301, it blocks the infrared rays emitted by the infrared emitter 301, and the infrared receiver 302 does not receive the infrared rays, so it sends a signal to the processing terminal. The terminal controls the hydraulic cylinder 319 to move, driving the displacement frame 320 to move downwards until the first spur gear 318 contacts the second spur gear 322. At this time, the first spur gear 318 rotates, driving the second spur gear... 322 rotates, the second spur gear 322 rotates, driving the first bevel gear 323 to rotate, the first bevel gear 323 rotates, driving the second bevel gear 324 to rotate, the second bevel gear 324 rotates, driving the square telescopic rod 325 to rotate, the square telescopic rod 325 rotates, driving the third bevel gear 326 to rotate, the third bevel gear 326 rotates, driving the fourth bevel gear 327 to rotate, and the fourth bevel gear 327 rotates, driving the rotating cylinder 328 to rotate. During the rotation of the rotating cylinder 328, when the groove 329 is facing upward, the pearlescent dry granule glaze in the hopper 312 falls into the groove 329. When the groove 329 is facing downward, the pearlescent dry granule glaze in the groove 329 falls along the discharge port 313 into the vibrating frame 307. The vibration of the vibrating frame 307 causes the pearlescent dry granule glaze to pass evenly through the screen 308 and fall onto the ceramic tile, making it easier to evenly spread the pearlescent dry granule glaze on the ceramic tile.

[0057] After the tile passes through the infrared transmitter 301, the infrared receiver 302 receives the signal from the infrared transmitter 301. The hydraulic cylinder 319 rotates, driving the displacement frame 320 to move upward, causing the second spur gear 322 to separate from the first spur gear 318. At this point, the pearlescent dry granule glaze no longer falls from the outlet 313. It should be noted that the amount of pearlescent dry granule glaze falling into the vibrating frame 307 each time is 1.2-1.5 times the actual amount of pearlescent dry granule glaze required for a single tile. This ensures that the density and speed of the pearlescent dry granule glaze falling through the screen 308 are relatively constant when the tile passes under the screen 308, thus ensuring the uniformity of the pearlescent dry granule glaze application and preventing a significant reduction in the amount of glaze applied at the rear of the tile.

[0058] Please refer to this carefully. Figures 7 to 10The anti-sticking mechanism 4 includes an agitator roller 401, which is rotatably connected to the inner cavity of the hopper 312. A third spur gear 402 is fixedly connected to one end of the agitator roller 401, and a fourth spur gear 403 is fixedly connected to one end of the rotating cylinder 328. The third spur gear 402 and the fourth spur gear 403 are in contact. A fixing frame 404 is fixedly connected to the outer wall of the discharge port 313. A first arc-shaped plate 405 and a second arc-shaped plate 406 are fixedly connected to the outer wall of the fixing frame 404. The second arc-shaped plate 406 is located on the first arc-shaped plate 405. Above 5, a movable plate 408 is slidably connected inside the rotating cylinder 328. A partition plate 407 extending to the inner wall of the groove 329 is fixedly connected to the top of the movable plate 408. A threaded rod 409 passing through the movable plate 408 is rotatably connected inside the rotating cylinder 328. A fifth bevel gear 410 is fixedly connected to the bottom end of the threaded rod 409. A sixth bevel gear 411 is rotatably connected to the outer wall of the fifth bevel gear 410 inside the rotating cylinder 328. A fifth spur gear 412 is fixedly connected to one end of the sixth bevel gear 411.

[0059] In this embodiment: when the rotating cylinder 328 rotates, it drives the fourth spur gear 403 to rotate, which in turn drives the third spur gear 402 to rotate. The third spur gear 402 then drives the stirring roller 401 to rotate, which in turn stirs the pearlescent dry granule glaze in the hopper 312 to prevent clumping or blockage. When the groove 329 faces upward, the pearlescent dry granule glaze enters the groove 329. Then, the rotating cylinder 328 rotates, which drives the fifth spur gear 412 to move. The fifth spur gear 412 contacts the first arc-shaped plate 405 and moves along the outer wall of the first arc-shaped plate 405, thereby driving the fifth spur gear 412 to rotate. The rotation of the fifth spur gear 412 drives the sixth bevel gear 411 to rotate, which in turn drives the fifth bevel gear 411 to rotate. The fifth bevel gear 410 rotates, causing the threaded rod 409 to rotate. The rotation of the threaded rod 409 causes the movable plate 408 to move, which in turn causes the partition plate 407 to move. The partition plate 407 moves into the groove 329, cutting the pearlescent dry granule glaze in the groove 329, thereby further preventing clumping. Then, the fifth spur gear 412 separates from the first arc plate 405 and contacts the second arc plate 406. The fifth spur gear 412 moves along the second arc plate 406, thereby causing the fifth spur gear 412 to rotate in the opposite direction, thereby causing the partition plate 407 to move out of the groove 329. After the fifth spur gear 412 separates from the second arc plate 406, the groove 329 faces downward, allowing the pearlescent dry granule glaze to fall. This design can easily prevent the pearlescent dry granule glaze from clumping or blocking in the hopper 312.

[0060] Please refer to this carefully. Figures 2 to 7The inner diameter of the limiting hole 309 is larger than the outer diameter of the limiting post 310.

[0061] In this embodiment: the protrusion 317 displaces and impacts the connecting plate 306, causing the connecting plate 306 and the vibration frame 307 to vibrate. When the connecting plate 306 vibrates, the limiting post 310 moves within the limiting hole 309 to limit the vibration amplitude of the connecting plate 306, preventing the vibration frame 307 from displacing and causing the pearlescent dry granule glaze to not fall onto the ceramic tile.

[0062] Please refer to this carefully. Figures 2 to 7 The first spur gear 318 meshes with the second spur gear 322, and the first bevel gear 323 meshes with the second bevel gear 324.

[0063] In this embodiment: the hydraulic cylinder 319 operates to drive the displacement frame 320 to move downward until the first spur gear 318 contacts the second spur gear 322. At this time, the first spur gear 318 rotates to drive the second spur gear 322 to rotate, the second spur gear 322 rotates to drive the first bevel gear 323 to rotate, and the first bevel gear 323 rotates to drive the second bevel gear 324 to rotate.

[0064] Please refer to this carefully. Figures 2 to 7 The third bevel gear 326 meshes with the fourth bevel gear 327.

[0065] In this embodiment: the rotation of the second bevel gear 324 drives the square telescopic rod 325 to rotate, the rotation of the square telescopic rod 325 drives the third bevel gear 326 to rotate, the rotation of the third bevel gear 326 drives the fourth bevel gear 327 to rotate, and the rotation of the fourth bevel gear 327 drives the rotating cylinder 328 to rotate.

[0066] Please refer to this carefully. Figures 7 to 10 The fourth spur gear 403 meshes with the third spur gear 402.

[0067] In this embodiment: when the rotating cylinder 328 rotates, it drives the fourth spur gear 403 to rotate, the rotation of the fourth spur gear 403 drives the third spur gear 402 to rotate, and the rotation of the third spur gear 402 drives the stirring roller 401 to rotate.

[0068] Please refer to this carefully. Figures 7 to 10 The inner side of the first arc plate 405 and the outer wall of the second arc plate 406 are both provided with tooth grooves, which mesh with the fifth spur gear 412.

[0069] In this embodiment: the rotating cylinder 328 rotates and drives the fifth spur gear 412 to move. When the fifth spur gear 412 moves and comes into contact with the inner wall of the first arc plate 405 and the outer wall of the second arc plate 406, the fifth spur gear 412 moves along the first arc plate 405 and the second arc plate 406, thereby driving the fifth spur gear 412 to rotate.

[0070] Please refer to this carefully. Figures 7 to 10 The sixth bevel gear 411 meshes with the fifth bevel gear 410, and the outer wall of the movable plate 408 is provided with a threaded hole, which matches the threaded rod 409.

[0071] In this embodiment: the rotation of the fifth spur gear 412 drives the sixth bevel gear 411 to rotate, the rotation of the sixth bevel gear 411 drives the fifth bevel gear 410 to rotate, the rotation of the fifth bevel gear 410 drives the threaded rod 409 to rotate, the rotation of the threaded rod 409 drives the movable plate 408 to move, and the movement of the movable plate 408 drives the partition plate 407 to move. Example 2

[0072] This embodiment provides a manufacturing process for pearlescent ceramic tiles, the specific steps of which are as follows:

[0073] Step 1: Preparation and Shaping of the Green Body: Select the following raw materials by weight, based on the total weight of the raw materials: 50 parts clay, 30 parts quartz, 20 parts feldspar, and 10 parts kaolin. Wetly ball-mill the raw materials into a slurry, spray-dry them into powder, and then press them into shape using a fully automatic hydraulic press to obtain the brick blank.

[0074] Step 2, Drying and Decoration: After the brick blanks are dried in the drying kiln, a preset solid color decorative pattern is printed on their surface using a high-definition digital inkjet printer.

[0075] Step 3: Apply surface glaze: Using a high-precision bell-shaped glaze spraying machine, apply surface glaze evenly to the surface of the brick body with the printed pattern. The amount of glaze applied is controlled at 460 g / ㎡ to form a moist glaze layer.

[0076] Step 4: Apply pearlescent dry granule glaze: While the surface glaze is still moist (within 45 seconds after application), evenly spread the pearlescent dry granule glaze onto the glaze surface using a pearlescent dry granule glaze spreader. The spreading amount is 100 g / ㎡. The pearlescent dry granule glaze, by weight, consists of the following components: a base glaze (35 parts silica sand, 25 parts borax, 13 parts soda ash, 8 parts zinc oxide, 6 parts calcium carbonate) mixed with 10% iron mica pearlescent pigment by weight of the base glaze, with a particle size of 100 mesh.

[0077] Step 5: Firing: The glazed brick blanks are fed into a fully automatic wide-body roller kiln and fired in an oxidizing atmosphere. The firing regime is as follows: firing at the highest temperature of 1200℃, with a total firing cycle of 60 minutes.

[0078] Step Six: Polishing, Inspection and Packaging: After firing, the tiles are gently polished after cooling, and after passing inspection, they are packaged and stored.

[0079] The equipment used in step four, such as the pearlescent dry granule glaze applicator, is the same as in Example 1, and will not be described again here. Example 3

[0080] This embodiment provides a manufacturing process for pearlescent ceramic tiles, the specific steps of which are as follows:

[0081] Step 1: Preparation and Shaping of the Green Body: Select the following raw materials by weight, based on the total weight of the raw materials: 55 parts clay, 25 parts quartz, 25 parts feldspar, and 15 parts kaolin. Wetly ball-mill the raw materials into a slurry, spray-dry them into powder, and then press them into shape using a fully automatic hydraulic press to obtain the brick blank.

[0082] Step 2, Drying and Decoration: After the brick blanks are dried in a drying kiln, a preset wood grain pattern is printed on their surface using a high-definition digital inkjet printer.

[0083] Step 3: Apply surface glaze: Use a high-precision bell-shaped glaze spraying machine to evenly apply surface glaze to the surface of the brick body with the printed pattern. The amount of glaze applied is controlled at 470g / ㎡ to form a moist glaze layer.

[0084] Step 4: Apply pearlescent dry granule glaze: While the surface glaze is still moist (within 30 seconds after application), evenly spread the pearlescent dry granule glaze onto the glaze surface using a pearlescent dry granule glaze spreader. The spreading amount is 110 g / ㎡. The pearlescent dry granule glaze, by weight, consists of the following components: a base glaze (40 parts silica sand, 20 parts borax, 15 parts soda ash, 5 parts zinc oxide, 8 parts calcium carbonate) mixed with 15% titanium mica pearlescent pigment by weight of the base glaze, with a particle size of 80 mesh.

[0085] Step 5: Firing: The glazed brick blanks are fed into a fully automatic wide-body roller kiln and fired in an oxidizing atmosphere. The firing regime is as follows: firing at the highest temperature of 1210℃, with a total firing cycle of 50 minutes.

[0086] Step Six: Polishing, Inspection and Packaging: After firing, the tiles are gently polished after cooling, and after passing inspection, they are packaged and stored.

[0087] The equipment used in step four, such as the pearlescent dry granule glaze applicator, is the same as in Example 1, and will not be described again here. Comparative Example 1

[0088] The only difference between this comparative example and Example 2 is that, in step four, the particle size of the pearlescent dry granule glaze is adjusted to 200 mesh; the remaining steps and parameters are exactly the same as in Example 2. Comparative Example 2

[0089] The only difference between this comparative example and Example 2 is that in step four, after drying the surface glaze layer in an oven at 110°C for 10 minutes until it is completely dry, the same proportion and amount of pearlescent dry granule glaze are applied. The remaining steps and parameters are exactly the same as in Example 2. Comparative Example 3

[0090] The only difference between this comparative example and Example 2 is that, in step five, the maximum firing temperature is adjusted to 1150°C; the remaining steps and parameters are exactly the same as in Example 2. Performance testing and effect analysis

[0091] The ceramic tile samples prepared in Examples 1-3 and Comparative Examples 1-3 were subjected to performance testing according to relevant national or industry standards. The specific testing items and methods are as follows:

[0092] 1. Pearlescent uniformity: Following the surface evaluation guidelines in GB / T 3810.14-2016 "Test Methods for Ceramic Tiles Part 14: Determination of Stain Resistance", three experienced inspectors visually evaluated the pearlescent layering, distribution uniformity, and softness of the tile surface from different angles (60°) under a standard light source box (D65 light source), and reached a consensus. Simultaneously, a colorimeter was used to measure the uniformity of surface gloss at multiple points.

[0093] Evaluation criteria: Excellent: uniform, smooth, and without obvious spots or agglomerations; Good: slight unevenness or dullness; Poor: obvious agglomeration, uneven distribution, or lack of effect.

[0094] 2. Gloss: According to GB / T 13891-2008 "Method for Determination of Specular Gloss of Building Facing Materials", a 60° geometric angle gloss meter was used to measure five points evenly selected on the surface of each sample. The arithmetic mean was taken and the unit was gloss unit (GU).

[0095] 3. Dry granule adhesion: Refer to GB / T 9286-2021 "Cross-cut test for paints and varnishes", use a cutting tool with a 1mm spacing to cut a grid from the sample glaze to the body, use special pressure-sensitive tape (3M 610) to stick it and quickly peel it off, and observe the peeling of the glaze (especially the pearlescent dry granules).

[0096] Evaluation criteria: 0-5, with 5 indicating a completely smooth cut edge and no chips falling off; and 0 indicating a chipping area greater than 65%.

[0097] 4. Stain resistance: According to Appendix M (Stain Test) of GB / T 4100-2015 "Ceramic Tiles". Apply easily contaminant (such as ink, red wine, olive oil) to the sample surface, let it stand for a specified time, clean it with the specified cleaning agent, and observe the residual traces.

[0098] Evaluation criteria: Level 5 indicates no visible changes; Level 1 indicates severe pollution.

[0099] 5. Abrasion Resistance: Tested according to GB / T 3810.7-2016 "Test Methods for Ceramic Tiles - Part 7: Determination of Abrasion Resistance of Glazed Tiles Surfaces", using a rotary abrasion tester (such as TABER). Evaluation Criteria: Report the number of rotations before visible wear marks appear.

[0100] 6. Flexural strength: According to GB / T 3810.4-2016 "Test methods for ceramic tiles - Part 4: Determination of modulus of rupture and breaking strength", the three-point bending method was used to determine the flexural strength on a universal testing machine.

[0101] Evaluation criteria: The unit is megapascal (MPa).

[0102] The specific test results for each sample are shown in the table below:

[0103]

[0104] In summary, through comparative analysis of the performance test data of the embodiments and comparative examples, it can be clearly seen that the test data of Examples 1-3 show that when the glaze layer is in a specific moist state, pearlescent dry granule glaze with a specific particle size is applied and the ceramic tile is fired in a specific high-temperature oxidizing atmosphere, the pearlescent effect is uniform and soft, and the gloss is stable within the ideal range of 35-38 GU. Most importantly, the adhesion between the pearlescent dry granules and the glaze surface reaches the optimal level 5. This directly ensures the product's excellent stain resistance, high wear resistance, and good flexural strength, verifying the effectiveness and process stability of this invention in solving the technical problem of "uniformity and durability of the pearlescent effect."

[0105] The comparative examples show that exceeding the particle size range protected by this invention leads to agglomeration of dry particles, disrupting pearlescent uniformity and reducing surface properties. Comparative Example 2 demonstrates that once the core process window of the "wet glaze state" is missed, the adhesion of dry particles drops sharply to level 2, triggering uneven distribution, a chain reaction of deterioration in stain resistance and abrasion resistance, highlighting the irreplaceable nature of the core steps of this invention. Comparative Example 3 confirms that firing temperatures below 1190°C cannot achieve sufficient melting and bonding between the glaze and dry particles, resulting in a significant decrease in the basic properties of the glaze, such as gloss and strength. The failures of the above comparative examples prove that this invention combines specific materials, specific process timing, and a specific sintering regime, producing unexpected synergistic effects. This is not a simple superposition of techniques in the field or a conventional choice, thus possessing outstanding substantive characteristics and significant progress.

[0106] The above description is merely a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A manufacturing process for pearlescent ceramic tiles, characterized in that, The specific steps are as follows: Step 1, Green Body Preparation and Forming: After weighing the raw materials for the green body according to the proportion, they are put into a ball mill for wet ball milling to make a slurry. The slurry is then dried in a spray drying tower to make granular powder, and then pressed into brick blanks by a fully automatic hydraulic press. Step 2, Drying and Decoration: The brick blanks are sent into a drying kiln for drying. After drying, decorative patterns are printed on the surface of the brick blanks. Step 3: Apply surface glaze: Apply a layer of moist surface glaze evenly to the surface of the brick blank after printing the pattern; Step 4: Apply pearlescent dry granule glaze: While the surface glaze is still wet, evenly sprinkle the pearlescent dry granule glaze onto the wet glaze surface; Step 5, Firing: The glazed brick blanks are sent into a roller kiln for firing, so that the surface glaze melts and combines with the pearlescent dry particles to form a glaze surface with a pearlescent effect. Step Six: Polishing, Inspection and Packaging: After firing, the tiles are cooled, polished, and inspected before being stored in the warehouse. In step four, the application of pearlescent dry granule glaze is carried out using a pearlescent dry granule glaze spreader. The pearlescent dry granule glaze spreader includes a first conveyor belt (1) and a second conveyor belt (2). The second conveyor belt (2) is positioned above the first conveyor belt (1). The first conveyor belt (1) is used to transport the ceramic tile, and the second conveyor belt (2) is used to transport the pearlescent dry granule glaze. The pearlescent dry granule glaze is applied to the ceramic tile by a spreading mechanism (3), and the pearlescent dry granule glaze is prevented from clumping or blocking by an anti-sticking mechanism (4). The spreading mechanism (3) includes an infrared transmitter (301) and an infrared receiver (302). The infrared transmitter (301) and the infrared receiver (302) are respectively installed on both sides of the first conveyor belt (1). A base (303) is provided below the first conveyor belt (1). A support seat (304) is symmetrically fixedly connected to the top of the base (303). A spring (305) is fixedly connected to the top of the support seat (304). A connecting plate (306) is fixedly connected to the top of the spring (305). A vibration frame (307) is fixedly connected between the two connecting plates (306). A screen (308) is fixedly connected to the bottom of the inner wall of the vibration frame (307). A limit hole (30) is opened on the outer wall of the connecting plate (306). 9) The top of the support base (304) is fixedly connected to the inner side of the spring (305) with a limiting post (310). The limiting post (310) passes through the limiting hole (309). The top of the base (303) is fixedly connected to a support frame (311) on one side of the support base (304). The top of the support frame (311) is fixedly connected to a hopper (312). The bottom of the hopper (312) is fixedly connected to a discharge port (313). A motor (314) is installed on one side of the support frame (311). The output end of the motor (314) is connected to a connecting shaft (315). One end of the connecting shaft (315) is fixedly connected to a rotating disk (316). The outer wall of the rotating disk (316) is fixedly connected to a protrusion (317). The spreading mechanism (3) further includes a first spur gear (318), which is fixedly connected to the outer wall of the connecting shaft (315). A hydraulic cylinder (319) is installed at the top of the inner wall of the support frame (311). The output end of the hydraulic cylinder (319) is connected to a displacement frame (320). The displacement frame (320) is slidably connected to the support frame (311). A fixed seat (321) is fixedly connected to the inner wall of the support frame (311) on one side of the hydraulic cylinder (319). A second spur gear (322) is rotatably connected to one side of the displacement frame (320). A first bevel gear (323) is fixedly connected to one end of the second spur gear (322). The first bevel gear (323) is rotatably connected inside the displacement frame (320). The displacement frame (320) is rotatably connected to the outer wall of the first bevel gear (323) and a second bevel gear (324). A square telescopic rod (325) is fixedly connected to the top of the second bevel gear (324). A third bevel gear (326) is fixedly connected to the top of the square telescopic rod (325). The third bevel gear (326) is rotatably connected to the inside of the fixed seat (321). A fourth bevel gear (327) is rotatably connected to the outer wall of the third bevel gear (326) and a rotating cylinder (328) is fixedly connected to one end of the fourth bevel gear (327). The rotating cylinder (328) is rotatably connected to the inside of the discharge port (313). A groove (329) is provided on the outer wall of the rotating cylinder (328).

2. The preparation process of the pearlescent effect ceramic tile according to claim 1, characterized in that... In step one, the raw materials for the green body, based on the total mass of the raw materials for the green body, include the following components: clay: 45-55 parts; Quartz: 25-35 parts; Feldspar: 15-25 parts; Kaolin: 5-15 parts.

3. The preparation process of pearlescent effect ceramic tiles according to claim 1, characterized in that... In step four, the amount of pearlescent dry granule glaze applied is 90-110 g / m²; the pearlescent dry granule glaze comprises a base glaze and a pearlescent effect material. The base glaze is a low-temperature transparent frit glaze, comprising, by weight: 30-40 parts silica sand, 20-30 parts borax, 10-15 parts soda ash, 5-10 parts zinc oxide, and 5-8 parts calcium carbonate; the pearlescent effect material is a mica-based pearlescent pigment, added at 5-15% of the total mass of the base glaze; the pearlescent dry granule glaze has a particle size of 80-150 mesh.

4. The preparation process of pearlescent effect ceramic tiles according to claim 1, characterized in that, In step three, the glaze application amount is 450-470 g / m²; in step four, the amount of pearlescent dry granule glaze applied is 90-110 g / m²; in step five, the firing is carried out in an oxidizing atmosphere, with a maximum firing temperature of 1190-1210℃ and a total firing cycle of 50-70 minutes.

5. The preparation process of a pearlescent ceramic tile according to claim 1, characterized in that, The anti-sticking mechanism (4) includes an agitator roller (401), which is rotatably connected to the inner cavity of the hopper (312). A third spur gear (402) is fixedly connected to one end of the agitator roller (401), and a fourth spur gear (403) is fixedly connected to one end of the rotating cylinder (328). The third spur gear (402) and the fourth spur gear (403) are in contact. A fixing frame (404) is fixedly connected to the outer wall of the discharge port (313). A first arc plate (405) and a second arc plate (406) are fixedly connected to the outer wall of the fixing frame (404). The second arc plate (406) is located on the first arc plate. Above (405), a movable plate (408) is slidably connected inside the rotating cylinder (328). A partition plate (407) extending to the inner wall of the groove (329) is fixedly connected to the top of the movable plate (408). A threaded rod (409) penetrating the movable plate (408) is rotatably connected inside the rotating cylinder (328). A fifth bevel gear (410) is fixedly connected to the bottom end of the threaded rod (409). A sixth bevel gear (411) is rotatably connected to the outer wall of the fifth bevel gear (410) inside the rotating cylinder (328). A fifth spur gear (412) is fixedly connected to one end of the sixth bevel gear (411).

6. The preparation process of a pearlescent ceramic tile according to claim 1, characterized in that, The inner diameter of the limiting hole (309) is larger than the outer diameter of the limiting post (310); the first spur gear (318) meshes with the second spur gear (322), the first bevel gear (323) meshes with the second bevel gear (324), and the third bevel gear (326) meshes with the fourth bevel gear (327).

7. The preparation process of a pearlescent ceramic tile according to claim 5, characterized in that, The fourth spur gear (403) meshes with the third spur gear (402); the inner side of the first arc plate (405) and the outer wall of the second arc plate (406) are both provided with tooth grooves, which mesh with the fifth spur gear (412).

8. The preparation process of a pearlescent ceramic tile according to claim 5, characterized in that, The sixth bevel gear (411) meshes with the fifth bevel gear (410), and the outer wall of the movable plate (408) is provided with a threaded hole, which matches the threaded rod (409).

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