Multi-specification ceramic tile integrated manufacturing method and ceramic tile

Abstract

The invention provides a multi-specification ceramic tile integrated manufacturing method and a ceramic tile. The method comprises the steps that the mold appearance size, the mold design seam size, the edging control size, the cutting seam size and the trimming seam size corresponding to a to-be-produced multi-specification ceramic mother tile are determined; a multi-specification integrated mold is designed and manufactured based on the mold appearance size, the mold design gap size and the required ceramic tile specification; a required green body is pressed by using a multi-specification integrated mold, and the green body is treated into a multi-specification ceramic mother brick based on the edge grinding control size; and based on the cutting seam size and the trimming seam size, the multi-specification ceramic mother bricks are separated into ceramic bricks of various specifications. Synchronous forming of ceramic tiles of various specifications is achieved by adopting the multi-specification integrated mold, the mold does not need to be replaced, glaze lines do not need to be transformed, the production cost is reduced, meanwhile, overall use parameters are calculated in advance, size deviation caused by multi-specification separation is avoided, and then the production efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of ceramic tile production technology, and in particular to an integrated manufacturing method for multi-specification ceramic tiles and ceramic tiles. Background Technology

[0002] As a core material in the field of building decoration, architectural ceramic tiles are mostly in the form of regular slabs or blocks such as squares and rectangles, but also include irregular shapes such as rhombuses and hexagons. The forming process is mainly divided into two categories: traditional mold pressing and belt press forming. Among them, ceramic tiles formed by belt press (some products are defined as slabs) need to be cut along the length of the blank to determine the final appearance size, while the traditional mold pressing process is more suitable for small-sized ceramic tiles or blanks whose shapes are not easy to cut, and has the advantage of convenient forming.

[0003] In traditional production models, the production of architectural ceramic tiles is significantly limited by the "one mold, one specification" principle. Different shapes and sizes of ceramic tiles require the design and development of dedicated molds, and changes in specifications inevitably necessitate mold replacements. This leads to extended production preparation cycles and increased mold development costs, which account for 35% to 45% of the cost of small-batch customized production. Furthermore, the glazing and decoration process parameters on the production line must strictly match the specifications of a single product. Mixing multiple specifications on the same line can easily cause problems such as chaotic transport of blanks and breakage due to collisions, directly resulting in a decrease in the product yield. Frequent specification changes also cause production line downtime for adjustments to exceed 20%, severely restricting the delivery efficiency of small-batch, multi-order orders.

[0004] Furthermore, with the increasing trend of consumption upgrading, the market demand for personalized architectural ceramic tiles is growing. The popularity of light luxury retro and personalized mixed-style decoration has led to over 80% of high-end residential and commercial spaces requiring the use of three or more types of ceramic tiles (such as antique-style tiles) simultaneously. The demand for flexibility in tile combinations is also increasing. Designers often use a variety of shapes, sizes, textures, and colors of ceramic tiles for mixed decoration to create a unique artistic atmosphere in consumer and living spaces. This type of decoration has become one of the mainstream preferences of young consumers. However, the ceramic tiles required for personalized mixed-style scenarios exhibit diverse differences in specifications and appearance. Traditional single-specification mass production models struggle to achieve efficient supply in small quantities. The average supply response cycle of traditional mass production is 25-30 days, far from meeting the 15-20 day delivery requirements of end users, resulting in a significant contradiction between production efficiency and personalized needs. In other words, existing technologies suffer from low production efficiency when producing multi-specification ceramic tiles.

[0005] Therefore, existing technologies have shortcomings and need to be improved and developed. Summary of the Invention

[0006] The technical problem to be solved by the present invention is to provide an integrated manufacturing method and ceramic tiles for multiple specifications, in order to address the above-mentioned deficiencies of the prior art, and to solve the problem of low efficiency in the production of multiple specifications of ceramic tiles in the prior art.

[0007] The technical solution adopted by this invention to solve the technical problem is as follows: A method for integrated manufacturing of multi-specification ceramic tiles, wherein the method includes: Determine the mold appearance dimensions, mold design gap dimensions, edge grinding control dimensions, cutting seam dimensions, and trimming seam dimensions corresponding to the multi-specification ceramic master bricks to be produced; Based on the mold's external dimensions, the mold's design gap dimensions, and the required ceramic tile specifications, a multi-specification integrated mold is designed and manufactured. The required blank is pressed using the multi-specification integrated mold, and the blank is processed into multi-specification ceramic master bricks based on the edge grinding control dimensions. Based on the cutting seam size and trimming seam size, the multi-specification ceramic mother brick is separated into ceramic bricks of various specifications.

[0008] In one embodiment of this application, determining the mold appearance dimensions, mold design gap dimensions, edge grinding control dimensions, cutting gap dimensions, and trimming gap dimensions corresponding to the multi-specification ceramic master bricks to be produced includes: Determine the required water absorption rate of the ceramic tile, and determine the firing shrinkage rate based on the water absorption rate; Determine the mold's external dimensions, and then determine the green body drying dimensions based on the mold's external dimensions; The fired appearance dimensions are calculated based on the drying dimensions of the green body and the firing shrinkage rate, and the edge grinding control dimensions are determined based on the fired appearance dimensions. Obtain the preset tiling gap size, and calculate the mold design gap size based on the preset tiling gap size and the firing shrinkage rate; The cutting seam size is determined based on the preset tiling gap size, and the trimming seam size is calculated based on the preset tiling gap size and the cutting seam size.

[0009] In one embodiment of this application, the fired appearance size is the product of the difference obtained by subtracting the firing shrinkage rate and the dried size of the green body; the mold design gap size is the ratio of the preset laying gap size to the difference obtained by subtracting the firing shrinkage rate; the cutting gap size is less than or equal to the preset laying gap size; and the trimming gap size is half the difference between the preset laying gap size and the cutting gap size.

[0010] In one embodiment of this application, based on the mold's external dimensions, the mold's design gap dimensions, and the required ceramic tile specifications, a multi-specification integrated mold is designed and manufactured, including: Based on the mold's external dimensions, the mold's design gap dimensions, and the required ceramic tile specifications, the layout is performed under the mold's external dimensions to obtain the divided mold sub-regions. Based on the divided mold sub-regions, multi-specification integrated molds are designed and manufactured. Each mold sub-region corresponds to a ceramic tile position, and there are mold design gap dimensions between each mold sub-region.

[0011] In one embodiment of this application, the multi-specification integrated mold has a decorative surface and a paving surface corresponding to each mold sub-region, the decorative surface having a predetermined effect edge, and the paving surface having a predetermined border.

[0012] In one embodiment of this application, the required blank is pressed using the multi-specification integrated mold, and the blank is processed into multi-specification ceramic master bricks based on the edge grinding control dimensions, including: The required blank is pressed using the multi-specification integrated mold, and the blank is processed into a fired ceramic brick with the appearance and size after firing according to the ceramic brick process flow. The fired ceramic bricks are edge-ground to obtain multi-specification ceramic master bricks with edge-ground control dimensions.

[0013] In one embodiment of this application, based on the cutting seam size and trimming seam size, the multi-specification ceramic mother brick is separated into ceramic bricks of various specifications, including: Based on the cutting seam size, the ceramic bricks of each specification on the multi-specification ceramic mother brick are separated to obtain the separated ceramic bricks of each specification. Based on the trimming seam size, the separation edges of the separated ceramic tiles of each specification are trimmed to obtain trimmed ceramic tiles of each specification.

[0014] In one embodiment of this application, the multi-specification ceramic master brick has grooves between the ceramic bricks of different specifications to display the outline of the ceramic bricks of different specifications.

[0015] In one embodiment of this application, after separating the multi-specification ceramic mother brick into ceramic bricks of various specifications based on the cutting seam size and trimming seam size, the method further includes: Ceramic tiles of various specifications are packaged and stored in the warehouse according to a single specification, or according to the proportion of ceramic tiles of various specifications in the predetermined combination paving scheme.

[0016] This application also provides a ceramic tile, which is manufactured by the multi-specification ceramic tile integrated manufacturing method described above.

[0017] This invention provides an integrated manufacturing method for multi-specification ceramic tiles and the ceramic tiles themselves. The method includes: determining the mold appearance dimensions, mold design gap dimensions, edge grinding control dimensions, cutting seam dimensions, and trimming seam dimensions corresponding to the multi-specification ceramic master tiles to be produced; designing and manufacturing a multi-specification integrated mold based on the mold appearance dimensions, mold design gap dimensions, and the required ceramic tile specifications; pressing the required blank using the multi-specification integrated mold; processing the blank into multi-specification ceramic master tiles based on the edge grinding control dimensions; and separating the multi-specification ceramic master tiles into ceramic tiles of various specifications based on the cutting seam dimensions and trimming seam dimensions. This application achieves simultaneous molding of multiple specifications of ceramic tiles by using a multi-specification integrated mold, eliminating the need to change molds and modify glaze lines, thus reducing production costs. Simultaneously, pre-calculating overall usage parameters avoids dimensional deviations caused by the separation of multiple specifications, thereby improving production efficiency. Attached Figure Description

[0018] Figure 1 This is a flowchart of a preferred embodiment of the integrated manufacturing method for multi-specification ceramic tiles in this invention.

[0019] Figure 2 This is a schematic diagram showing the external dimensions of the multi-specification ceramic master brick in this invention.

[0020] Figure 3 This is a schematic diagram of the cutting and separation of multi-specification ceramic mother bricks in this invention.

[0021] Figure 4 This is a schematic diagram of the trimming of the sub-brick in this invention.

[0022] Figure 5 This is a front view of the multi-specification ceramic master brick pressed by the multi-specification integrated mold in this invention.

[0023] Figure 6 This is a back view of the multi-specification ceramic master brick pressed by the multi-specification integrated mold in this invention.

[0024] Figure 7 The present invention refers to the multi-specification ceramic master bricks and the separated daughter bricks prepared in this invention.

[0025] Figure 8 These are the paving diagrams and real-life images of the multi-specification mixed-set ceramic tiles obtained in Embodiment 1 of this invention; Figure 9 This is a schematic diagram of the tiling assembly kit obtained in Embodiment 2 of the present invention.

[0026] Figure 10 This is a schematic diagram of the tiling assembly kit obtained in Embodiment 3 of the present invention.

[0027] Figure 11 This is a schematic diagram of the tiling assembly kit obtained in Embodiment 4 of the present invention. Detailed Implementation

[0028] To make the objectives, technical solutions, and advantages of this invention clearer and more explicit, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0029] While existing technologies include processes for cutting and separating large-format base bricks to obtain various sub-format products, this approach is only suitable for flat bricks without fixed antique edges or grooves. While the cutting position can be flexibly adjusted, it cannot achieve a decorative effect with a natural antique texture. Existing technologies for producing multi-format ceramic tiles only meet the basic requirements of GB / T 4100-2015 in key indicators such as dimensional accuracy deviation ±0.8mm and static friction anti-slip coefficient ≤0.5. They fail to meet the performance requirements of high-end market 5A-grade ceramic tiles (dimensional deviation ±0.2mm, static friction coefficient ≥0.6, wear resistance grade ≥4). Furthermore, existing cutting and separation technologies result in edge flatness deviations exceeding 1mm, easily leading to uneven joints after installation and hindering promotion and application in the high-end market.

[0030] For ceramic tile products with fixed exterior or decorative effects (such as antique edges), existing technologies still have the following limitations: First, the use of multiple sets of molds for step-by-step molding requires multiple technical modifications to the production glaze lines and repeated glazing and decoration processes, resulting in a cumbersome production process and increased costs. Second, while products using a one-time molding process without cutting and separation are somewhat similar to this invention in terms of molding method, the lack of consideration for dimensional accuracy control after cutting and separation simplifies the production process but fails to achieve independent mixed-and-matched decorative effects, merely serving an imitation function. This can easily lead consumers to perceive the product as low-end and low-cost, which does not meet the market's demand for high-quality, personalized decorative products.

[0031] In summary, existing technologies cannot effectively solve the problem of small-batch, high-efficiency production of ceramic tiles with fixed decorative effects (such as antique edges) and the ability to independently mix and match multiple specifications. How to break through the limitations of traditional production models and achieve integrated molding and precise separation of ceramic tiles with fixed decorative effects in multiple specifications to meet the market's personalized decoration needs has become a technical problem that the building ceramic tile industry urgently needs to solve.

[0032] This invention aims to address the core technical pain points in the existing production of architectural ceramic tiles: First, due to the limitation of "one mold, one specification" under the traditional production model, changing product specifications requires frequent mold changes, resulting in a complicated production process and high costs, which cannot meet the demand for multi-specification products required for personalized mixing. Secondly, the glazing and decoration processes of a single-specification production line are not compatible. If multiple specifications of products are produced at the same time, it is easy to cause problems such as transportation chaos and body breakage, which restricts the improvement of the product quality rate. Third, existing technologies make it difficult to achieve integrated mass production of ceramic tiles of various specifications and colors, which cannot meet the market's demand for small-batch, high-efficiency supply of personalized mixed-and-matched decorative tiles. At the same time, traditional cutting and separating processes are prone to dimensional deviations, affecting the paving effect.

[0033] This invention optimizes mold design, production process, and cutting technology to achieve one-time molding and precise separation of multi-specification ceramic tiles, solving the technical problems of low production efficiency, high cost, and insufficient dimensional accuracy in multi-specification products. Using this invention, various personalized ceramic tiles with different shapes, specifications, patterns, and colors can be produced simultaneously.

[0034] The following description, with reference to the accompanying drawings, illustrates an integrated manufacturing method for multi-specification ceramic tiles and the ceramic tiles themselves, according to embodiments of this application. Addressing the low production efficiency in the related technologies mentioned in the background section regarding the production of multi-specification ceramic tiles, this application provides an integrated manufacturing method for multi-specification ceramic tiles. In this method, the external dimensions of the mold corresponding to the multi-specification ceramic master tile to be produced, the mold design gap size, the edge grinding control size, the cutting seam size, and the trimming seam size are determined. Based on the mold external dimensions, the mold design gap size, and the required ceramic tile specifications, a multi-specification integrated mold is designed and manufactured. The required blank is pressed using the multi-specification integrated mold, and based on the edge grinding control size, the blank is processed into multi-specification ceramic master tiles. Based on the cutting seam size and the trimming seam size, the multi-specification ceramic master tile is separated into ceramic tiles of various specifications. This application achieves simultaneous molding of multiple specifications of ceramic tiles by using a multi-specification integrated mold, eliminating the need to change molds and modify glaze lines, thus reducing production costs. Simultaneously, pre-calculating overall usage parameters avoids dimensional deviations caused by the separation of multiple specifications, thereby improving production efficiency.

[0035] Please see Figure 1 , Figure 1 This is a flowchart of the integrated manufacturing method for multi-specification ceramic tiles in this invention. (For example...) Figure 1 As shown in the embodiment of the present invention, the integrated manufacturing method for multi-specification ceramic tiles includes: Step S100: Determine the mold appearance dimensions, mold design gap dimensions, edge grinding control dimensions, cutting seam dimensions, and trimming seam dimensions corresponding to the multi-specification ceramic master bricks to be produced.

[0036] In this embodiment of the application, step S100 specifically includes: Step S110: Determine the required water absorption rate of the ceramic tile, and determine the firing shrinkage rate based on the water absorption rate; Step S120: Determine the mold's external dimensions, and determine the green body drying dimensions based on the mold's external dimensions; Step S130: Calculate the fired appearance size based on the dried size of the green body and the firing shrinkage rate, and determine the edge grinding control size based on the fired appearance size; Step S140: Obtain the preset tiling gap size, and calculate the mold design gap size based on the preset tiling gap size and the firing shrinkage rate; Step S150: Determine the cutting seam size based on the preset tiling gap size, and calculate the trimming seam size based on the preset tiling gap size and the cutting seam size.

[0037] For example, in the parameter calculation stage, the required water absorption rate of the ceramic tile is selected, denoted by E%. The water absorption rate of the ceramic tile is related to the ceramic powder formulation, molding and pressing parameters, and firing regime. Selecting the required water absorption rate facilitates the subsequent acquisition of firing shrinkage rate, which is beneficial for stabilizing the appearance and dimensions of the product after firing, thereby calculating various dimensions of the embodiments of this application. In order to comply with the standard of "GB / T 45817-2025 Consumer Product Quality Classification Ceramic Tiles", the selected water absorption rate is no greater than 3%, and the water absorption rate range of the ceramic tile in the embodiment is controlled between 0.05% and 0.11%. Since the water absorption rate E < 0.2%, according to the 5A classification requirements, it is not necessary to test the uniformity of water absorption rate, which meets the 5A standard.

[0038] The firing shrinkage rate of the ceramic brick powder used is determined based on the water absorption rate, and the firing shrinkage rate is denoted by S. 烧 Specifically, the powder used in ceramic tile production, corresponding to the water absorption rate, generally has a relatively fixed powder formula, pressing parameters, and firing regime. The firing shrinkage rate can be obtained from production data. This application has broad applicability to the powder formula requirements for ceramic tiles, regardless of whether it is porcelain, stoneware, stoneware-based, or earthenware body powder, and regardless of whether it is high whiteness or environmentally friendly body powder with added waste porcelain powder or some slag. The ceramic tiles provided in the embodiments of this application are bodies made of porcelain powder. By weight percentage, the formula contains 16-20% pressed polishing mud (sediment obtained from the treatment of wastewater from ceramic tile edge grinding and polishing) and waste porcelain powder (porcelain powder after recycling and crushing of waste ceramic tiles), with a firing shrinkage rate S. 烧 The chemical composition of the raw material used in the ceramic bricks of this embodiment, by weight percentage, includes: loss on ignition 4.97%, SiO2 67.71%, Al2O3 19.12%, Fe2O3 1.53%, CaO 0.48%, MgO 1.60%, K2O 2.08%, Na2O 2.01%, with the balance being impurities.

[0039] Determine the external dimensions of the mold. If it is a square, the side length is represented by L0; if it is a rectangle, the length and width are represented by L1 and L2 respectively. 01 L02 This indicates that after the green body is pressed and demolded, it will expand to a certain extent, and its external dimensions will be greater than L0, or L... 01 L 02 After drying in the kiln, the external dimensions of the green body are fixed. The dried dimensions of square green bodies are represented by L0', such as... Figure 2 As shown; the drying dimensions of the green body of the rectangular product are represented by L. 01 ´、L 02 The mold's external dimension L0 in this embodiment is 673mm; the dried dimensions of the green body after pressing and drying are fixed at 677mm to 678mm.

[0040] After firing, the external dimensions of the square product are represented by L1, such as... Figure 2 As shown; the dimensions of the long and short sides of the rectangular product after firing are represented by L. 11 L 12 It means; where L1 = L0' × (1-S) 烧 ), or L 11 = L 01 ×(1-S 烧 ), L 12 = L 02 ×(1-S 烧 In this embodiment, the fired appearance dimension L1 is controlled to be 609mm to 612mm.

[0041] Obtain the preset grout spacing, denoted by D0. Specifically, when laying ceramic tiles, grout gaps are generally required, with common gap sizes being 1mm, 1.5mm, 2mm, 2.5mm, and 3mm. Calculate the mold design grout spacing based on the firing shrinkage rate, denoted by D0'. In this embodiment, the preset grout spacing of the end product is 3mm, and the actual cutting and separation gap size of the mold design (i.e., the mold design grout spacing) is 3.3mm.

[0042] Determine the usable external dimensions of the product. For a square product, the usable external dimensions are represented by L2; for a rectangular product, the usable external dimensions are represented by L. 21 L 22 The product's usable dimensions refer to the dimensions after firing, after which excess dimensions are cut and ground away using edge-grinding equipment. The remaining product dimensions are the actual usable dimensions, i.e., the edge-grinding control dimensions. Figure 2As shown. For example, if the product's final dimensions after firing are 612mm × 1220mm, then 12mm needs to be ground off the short side, equivalent to 6mm being ground off each of the two opposite sides; 20mm needs to be ground off the long side, equivalent to 10mm being ground off each of the two opposite sides, resulting in an actual product size of 600mm × 1200mm. In this technical example of the invention, the final dimensions (edge ​​grinding control dimensions) L2 are controlled to be 600mm ± 0.2mm.

[0043] Based on the product's preset tiling gap size, select a cutting blade smaller than the preset tiling gap size D0. The cutting blade size is represented by D1. A cutting blade is required when cutting the product; the blade thickness is the cutting gap size. The thickness of the cutting blade is typically 1.2mm to 3.0mm, and the cutting gap size D1 must always be less than or equal to the preset tiling gap size D0 (D1 ≤ D0). For example, this application embodiment uses a 2mm diamond abrasive cutting blade. The preset tiling gap, cutting gap, and trimming gap in this application are as follows... Figure 3 and Figure 4 As shown.

[0044] In one embodiment of this application, the fired appearance size is the product of the difference obtained by subtracting the firing shrinkage rate and the dried size of the green body; the mold design gap size is the ratio of the preset laying gap size to the difference obtained by subtracting the firing shrinkage rate; the cutting gap size is less than or equal to the preset laying gap size; and the trimming gap size is half the difference between the preset laying gap size and the cutting gap size.

[0045] Specifically, the formula for calculating the fired appearance dimensions is: L1 = L0´ × (1 - S 烧 The formula for calculating the gap size in mold design is: D0´= D0 / (1-S 烧 The formula for calculating the trim seam size is: D2=(D0-D1) / 2.

[0046] This application embodiment ensures the dimensional accuracy of multi-specification products (using an external dimension control of 600mm±0.2mm) by precisely controlling the water absorption rate (0.05%~0.11%), firing shrinkage rate (9.7%~10.1%), and edge grinding and cutting parameters. The cutting seam size matches the tiling seam, effectively avoiding uneven tiling gaps and improving the decorative effect.

[0047] like Figure 1 As shown in the embodiment of the present invention, the integrated manufacturing method for multi-specification ceramic tiles further includes: Step S200: Based on the mold's external dimensions, the mold's design gap dimensions, and the required ceramic tile specifications, design and manufacture a multi-specification integrated mold.

[0048] In this embodiment of the application, step S200 specifically includes: Step S210: Based on the mold's external dimensions, the mold's design gap size, and the required ceramic tile specifications, the layout is performed under the mold's external dimensions to obtain the divided mold sub-regions; Step S220: Based on the divided mold sub-regions, design and manufacture multi-specification integrated molds, wherein each mold sub-region corresponds to a ceramic tile position, and there are mold design gap dimensions between each mold sub-region.

[0049] For example, based on the calculated parameters and preset parameters, a multi-specification integrated mold is designed and manufactured, and the required blank is pressed using the multi-specification integrated mold. Figure 3 As shown, the ceramic tiles are located in the mixed set of ceramic tiles B1, B2, B3, B4, and B5.

[0050] This application's embodiments break through the traditional "one mold, one specification" production limitation. Through multi-specification integrated mold design, it realizes the simultaneous molding and mass production of ceramic tiles of various specifications, eliminating the need for frequent mold changes, greatly simplifying the production process, and reducing mold development and production switching costs.

[0051] In one embodiment of this application, the multi-specification integrated mold has a decorative surface and a paving surface corresponding to each mold sub-region, the decorative surface having a predetermined effect edge, and the paving surface having a predetermined border.

[0052] For example, this application designs and manufactures multi-specification mixed-set grooves, with the front decorative surface groove edge having an antique edge (such as...). Figure 5 The mold shown has a square border around the groove on the back (as indicated). Figure 6 (As shown). Antique edges refer to ceramic tiles with naturally damaged edges, a decorative effect that mimics the worn, vintage texture. After cutting and separating, the grooved surface of the tile has a distinct square border, similar to a molded tile formed from a single mold, enhancing the user experience and perceived quality of the product.

[0053] The front of the decorative surface of the product in this application embodiment has a predetermined effect edge design (such as an antique edge). After cutting and trimming, the four edges still have a standard predetermined edge effect (such as an antique edge effect). It is not a simple cut after one-piece molding. It meets the personalized decoration needs of multiple specifications, colors and patterns for predetermined effects (such as retro and distressed), and broadens the application scenarios of the product.

[0054] like Figure 1 As shown in the embodiment of the present invention, the integrated manufacturing method for multi-specification ceramic tiles further includes: Step S300: Press the required blank using the multi-specification integrated mold, and process the blank into multi-specification ceramic master bricks based on the edge grinding control dimensions.

[0055] In this embodiment of the application, step S300 specifically includes: Step S310: Press the required green body using the multi-specification integrated mold, and process the green body into a fired ceramic brick with the appearance and size after firing according to the ceramic brick process flow. Step S320: Grind the edges of the fired ceramic bricks to obtain multi-specification ceramic master bricks with edge grinding control dimensions.

[0056] For example, ceramic tile A is obtained by glazing, decorating, and firing according to the required process flow for the product; ceramic tile A has an external dimension of L1 or L after firing. 11 L 12 First, the edges of ceramic tile A are ground to standardize its dimensions, resulting in ceramic tile B. The dimensions of ceramic tile B are the actual usable dimensions L2 or L... 21 L 22 The external dimensions of the multi-specification ceramic mother bricks before cutting and separation of the product of this invention are as follows: Figure 2 As shown.

[0057] The production process of this application embodiment is stable in terms of glazing, decoration, firing and other processes. It does not require adjustment for a single specification, nor does it require changing to multiple specifications or making multiple molds. This reduces the risk of collision and breakage of the blank and improves the product quality rate.

[0058] like Figure 1 As shown in the embodiment of the present invention, the integrated manufacturing method for multi-specification ceramic tiles further includes: Step S400: Based on the cutting seam size and trimming seam size, separate the multi-specification ceramic mother brick into ceramic bricks of various specifications.

[0059] In this embodiment of the application, step S400 specifically includes: Step S410: Based on the cutting seam size, separate the ceramic tiles of each specification on the multi-specification ceramic mother brick to obtain the separated ceramic tiles of each specification. Step S420: Based on the trimming seam size, trim the separation edges of the separated ceramic tiles of each specification to obtain trimmed ceramic tiles of each specification.

[0060] Specifically, ceramic tile B is cut. The purpose of this cutting is to separate the multi-sized mixed ceramic tiles after firing into the required sizes. The separated products of various sizes, B1, B2, B3, B4, B5…, can also be separated into different sizes using a tile-cutting machine instead of cutting. After separation, the cut edges of products B1, B2, B3, B4, B5... are trimmed to ensure proper dimensions. When the cut seam size is smaller than the preset installation gap size, each size of product will have an extra trimming seam D2 on its cut edges. The trimming seam size D2 for each edge is calculated as follows: D2 = (D0 - D...) 1) / 2, Note that this is not the edge grinding area produced by the edge grinding process; the cutting and trimming diagram is as follows. Figure 2 As shown. In this embodiment of the application, the trimming seam size of the cut and separated edge is 0.5mm. A schematic diagram of the mother brick cutting and separating and the daughter brick trimming is shown below. Figure 3 and Figure 4 Before the mother brick is cut and separated, the child bricks with traditional cultural totem symbols on their surface are designed as follows: Figure 7 As shown. The product, with its edges trimmed and dimensions standardized, is dried to obtain a multi-specification mixed set of ceramic tiles after separation.

[0061] In one embodiment of this application, the multi-specification ceramic master brick has grooves between the ceramic bricks of different specifications to display the outline of the ceramic bricks of different specifications.

[0062] like Figure 5 and Figure 6 As shown, both the front decorative surface and the back paving surface have grooves that clearly show the outline of the ceramic tiles in a multi-size set.

[0063] In this embodiment of the application, after step S400, the method further includes: packaging ceramic tiles of each specification into a warehouse according to a single specification, or packaging them into a warehouse according to the proportion of ceramic tiles of each specification in a predetermined combination paving scheme.

[0064] Specifically, multi-specification mixed ceramic tiles can be packaged and stored as single specifications or according to the proportion of the combined paving scheme. In this embodiment, a 600mm×600mm mother ceramic tile B is used, and based on this, three sub-ceramic tiles of specifications of 399mm×399mm, 399mm×198mm, and 198mm×198mm are cut and separated.

[0065] This application can be packaged and stored in accordance with the combined paving scheme according to the proportions, or it can be customized according to the customer's needs to create a personalized decoration, which is convenient for downstream construction and improves the efficiency of supply and demand matching. At the same time, it is compatible with both cutting and tile marking separation methods, adapting to the needs of different production scenarios.

[0066] For example, the parameter list of this application is shown in Table 1, and the product performance parameters are shown in Table 2.

[0067] Table 1

[0068] Table 2

[0069] The water absorption rate selected in this invention is for illustrative purposes and is not limited to this invention. The water absorption rate can be extended to the national standard range for water absorption rate classification of ceramic tiles. The firing shrinkage of this invention is also not limited to the above range. The magnitude of firing shrinkage is related to the raw materials used by the enterprise, the molding process, the firing process, etc. This invention only uses the above range as an example. Based on the magnitude of firing shrinkage, the design dimensions of the antique edge and cutting seam of this patented technology can be calculated. The multi-specification mixed set scheme listed in this invention is not unique; more mixed-specification ceramic tile sets can be designed. Square sub-tiles are required to have the same four sides after separation. Rectangular sub-tiles are required to have a shorter side equal to the side length of the smaller square sub-tile and a longer side equal to the side length of the larger square sub-tile.

[0070] The following are specific examples for illustration.

[0071] Example 1: Step A1: Select ceramic tiles with a water absorption rate of 0.05% to 0.11%, and control the appearance size after edge grinding to 600mm ± 0.2mm; the firing shrinkage rate is 9.7%, the green body drying size is 677mm, the fired appearance size is 611mm, the preset laying gap is 3mm, the calculated mold design gap is 3.3mm, the matching cutting gap is 2mm (cutting gap ≤ laying gap), and the trimming gap is 0.5mm; Step A2: Based on the above parameters, design and manufacture an integrated mold with a multi-specification mixed set and an antique-style edge on the front decorative surface. Use this mold to press and obtain a green body with a drying size of 677mm. Step A3: After glazing and decorating the body according to the preset process, it is sent into the kiln for firing to obtain ceramic tile A with a fired appearance size of 611mm. The decorative front and the back of the tile have grooves with the outline of multiple specifications. Step A4: Grind the edges of ceramic tile A to straighten its dimensions, resulting in ceramic tile B with a dimension of 600mm ± 0.2mm after grinding. Step A5: Use a 2mm thick diamond cutting blade to cut and separate the ceramic tile B along the contour groove. Step A6: Trim the edges of each sub-product after cutting and separating them. The trimming amount is controlled to 0.5mm to ensure that the appearance dimensions are regular. Finally, sub-products with three specifications of 399mm×399mm, 399mm×198mm and 198mm×198mm are obtained. Step A7: Dry the products of each specification after trimming to remove moisture, then package them into three specifications for storage. The actual installation effect of the mixed tiling kit is shown below. Figure 8 As shown.

[0072] Example 2: Step B1: Select ceramic tiles with a water absorption rate of 0.05% to 0.11%, and control the appearance size after edge grinding to 600mm ± 0.2mm; the firing shrinkage rate is 9.7%, the green body drying size is 678mm, the fired appearance size is 612mm, the preset laying gap is 2.5mm, the calculated mold design gap is 2.8mm, the matching cutting gap is 2mm (cutting gap ≤ laying gap), and the trimming gap is 0.25mm; Step B2: Design a multi-specification mixed mold with an antique edge according to the parameters, and press it to obtain a green body with a drying size of 678mm; Step B3: Perform glazing, decoration and firing processes on the body to obtain ceramic tile A with a fired appearance size of 612mm, whose surface grooves clearly show multi-specification outlines. Step B4: Grind the ceramic tile A with an edge grinding device to make its external dimensions 600mm ± 0.2mm, thus obtaining ceramic tile B; Step B5: Select a 2mm diamond cutting blade and cut along the contour groove of ceramic tile B to separate the initial sub-products. Step B6: Trim the cut edges of each sub-product, controlling the trimming seam to 0.25mm, and correct the dimensional deviation after cutting; finally, three specifications of sub-products are obtained: 399.1mm×399.1mm, 399.1mm×198.3mm, and 198.3mm×198.3mm. Step B7: After drying and trimming the product, remove surface moisture, and assemble and package the products according to the above sub-specifications in a 1:2:2 ratio for warehousing. Figure 9 As shown, this ensures the product's adaptability in scenarios with a 2.5mm tiling gap.

[0073] Example 3: Step C1: Select ceramic tiles with a water absorption rate of 0.05% to 0.11%, and control the appearance size after edge grinding to 600mm ± 0.2mm; the firing shrinkage rate is 10%, the green body drying size is 678mm, the fired appearance size is 610mm, the preset laying gap is 2mm, the calculated mold design gap is 2.2mm, the matching cutting gap is 1.5mm (cutting gap ≤ laying gap), and the trimming gap is 0.25mm; Step C2: Design a multi-specification mixed set of antique edge molds to press the billet to a green blank drying size of 678mm; Step C3: After glazing, decoration and firing processes, ceramic tile A with a fired appearance size of 610mm is obtained, and the grooves on the front and back sides are clearly marked with the division boundaries of multiple specifications. Step C4: Grind the edges of ceramic tile A to precisely control its dimensions to 600mm ± 0.2mm, thus producing ceramic tile B; Step C5: Using a 1.5mm thick diamond cutting blade, cut and separate ceramic tile B along the groove to initially obtain three independent sub-products of different specifications. Step C6: Trim the cut edges of each sub-product by 0.25mm to ensure that the dimensions are regular and the edges are smooth; finally, three specifications of sub-products are obtained: 399.4mm×399.4mm, 399.4mm×198.7mm, and 198.7mm×198.7mm. Step C7: After drying the product, assemble and package the products according to the above sub-specifications in a 1:3:2 ratio for warehousing. Figure 10 As shown, it meets the construction requirements for scenarios with a 2mm tiling gap, ensuring uniform tiling gaps.

[0074] Example 4: Step D1: Select ceramic tiles with a water absorption rate of 0.05% to 0.11%, and control the appearance size after edge grinding to 600mm ± 0.2mm; the firing shrinkage rate is 10%, the green body drying size is 677mm, the fired appearance size is 609mm, the preset laying gap is 1mm, the calculated mold design gap is 1.1mm, the tiles are separated using a tile cutting machine, and the edge trimming gap is 0.5mm; Step D2: Design a multi-specification mixed set of antique edge molds to press and obtain a green body with a drying size of 677mm; Step D3: After glazing and decorating the blank, it is sent into the kiln for firing to obtain ceramic tile A with a fired appearance size of 609mm. The groove on its surface provides a positioning reference for tile separation. Step D4: Grind ceramic tile A to 600mm ± 0.2mm using an edge grinding device to obtain ceramic tile B; Step D5: Given that the preset grout line is 1mm, instead of using a cutting blade, a tile cutting machine is used to cut and separate the ceramic tile B along the contour groove to avoid the cutting seam being too wide and affecting the paving effect. This initially yields three specifications of sub-products. Step D6: Trim the edges of the preliminarily cut sub-products by 0.5mm to correct minor dimensional deviations caused by cutting and ensure neat edges; finally, three specifications of sub-products are obtained: 399.6mm×399.6mm, 399.6mm×199.3mm, and 199.3mm×199.3mm. Step D7: After drying and trimming the product, remove moisture and then assemble and package it according to the above sub-specifications in a 2:1:6 ratio for warehousing. Figure 11 As shown, this ensures the product's fit and aesthetics in scenarios with 1mm narrow gaps.

[0075] This application breaks through the limitations of existing building ceramic tile production technology and is significantly different from existing technologies: First, the innovative combination of product form and production mode. In existing technologies, ceramic tiles with fixed antique edges need to be produced in multiple steps using multiple sets of molds, or formed in one piece but not cut and separated (without independent mixing and matching effects); while the large-format mother tile cutting process is only applicable to flat tiles without antique edges. This application is the first to realize the integrated production of tiles with fixed antique edges and independent mixing and matching of multiple specifications. Through a special mold, the ceramic tile has an antique edge on the front and pre-set multi-specification outline grooves on both the front and back. After cutting and separating, it still maintains the standard antique edge effect of four sides, filling the industry gap where the antique texture and multi-specification mixing and matching cannot be achieved at the same time.

[0076] Second, the coordinated design of dimensional parameters. This application innovatively proposes a full-process parameter coordinated control system for water absorption rate, firing shrinkage rate, laying seam, cutting seam, and trimming seam. Through precise calculation using the formula D2=(D0-D1) / 2, the trimming seam is matched with the laying seam and cutting seam, ensuring the dimensional accuracy and laying flatness of the product after cutting and separation. This can solve the dimensional cutting deviation caused by uneven firing shrinkage of the product. Existing technologies do not involve such multi-parameter collaborative optimization design.

[0077] Third, the uniqueness of the mold and product structure. The mold design of this application integrates the design of multi-specification contour grooves, antique edge on the front, and square frame on the back. After cutting, the square frame on the back gives the product the texture of being formed by an independent mold, which enhances the product grade. This mold structure is different from traditional single-specification molds and is also significantly different from existing multi-specification molds without antique edge and molds that are not cut and separated.

[0078] Fourth, flexible adaptation of separation methods. This application is compatible with two separation methods, namely diamond abrasive cutting and tile cutting machine, for different paving joint sizes in the conventional range of 1mm to 3mm. When the paving joint is ≤1mm, the tile cutting machine is used to avoid the cutting joint being too wide and affecting the effect. Existing technology does not consider the adaptation and optimization scheme between paving joint and separation method.

[0079] Therefore, this application achieves the following effects: First, it breaks through the core limitations of traditional production models. Addressing the high costs and low efficiency caused by the existing "one mold, one specification" approach, it innovatively adopts an integrated mold to achieve simultaneous molding of three or more specifications of ceramic tiles, eliminating the need to change molds or modify glaze lines. This simplifies the production process by more than 50% and significantly reduces mold development and production switching costs.

[0080] Secondly, this application addresses the challenge of dimensional accuracy in multi-specification antique-style edge products. Existing technologies often result in edge damage and dimensional deviations when cutting multiple specifications, making it even more difficult to maintain the texture of antique-style edges. This application pre-calculates overall usage parameters, pre-sets contour grooves, and employs precise edge trimming processes. This ensures that the cut sub-products maintain the integrity of the antique edge while achieving dimensional accuracy control of ±0.2mm, overcoming the technical contradiction between cutting separation and preserving the antique effect.

[0081] Third, it achieves full-chain adaptation between production and application. It innovatively proposes a packaged solution based on the combination paving ratio, which directly connects the needs of the production end and the construction end, while supporting customers to customize the mixing ratio, solving the problem of inefficient supply and demand matching of existing multi-specification products; and the parameter design covers all conventional paving joint scenarios from 1mm to 3mm, with adaptability far exceeding that of existing single-scenario technologies.

[0082] Furthermore, this application allows for the design of cultural patterns on the surface of sub-specifications when designing molds or textures. For example, it allows for the addition of outlines of Dunhuang caissons, Huizhou brick carvings, and other patterns to the antique-style edge, achieving the decoration of cultural elements through digital inkjet printing. For specific markets, the width, depth, and geometric patterns of the antique-style edge curvature can be adjusted to ensure that the sub-specification products after cutting and separation still meet the aesthetic preferences of the specific market. This application can adapt to the high-end market demand for both cultural and physical attributes. Compared to the existing technology of one mold per brick, ceramic tiles produced using this application have a 30%–40% lower mold manufacturing cost for batch production. Damaged edges do not need to be discarded entirely; after cutting and separation, complete sub-specification products remain, increasing the overall production yield to over 99%.

[0083] This application also provides a ceramic tile, which is manufactured by the multi-specification ceramic tile integrated manufacturing method described above.

[0084] In summary, this invention discloses an integrated manufacturing method for multi-specification ceramic tiles and the ceramic tiles themselves. The method includes: determining the mold appearance dimensions, mold design gap dimensions, edge grinding control dimensions, cutting seam dimensions, and trimming seam dimensions corresponding to the multi-specification ceramic master tiles to be produced; designing and manufacturing a multi-specification integrated mold based on the mold appearance dimensions, mold design gap dimensions, and the required ceramic tile specifications; pressing the required blank using the multi-specification integrated mold; processing the blank into multi-specification ceramic master tiles based on the edge grinding control dimensions; and separating the multi-specification ceramic master tiles into ceramic tiles of various specifications based on the cutting seam dimensions and trimming seam dimensions. This application achieves simultaneous molding of multiple specifications of ceramic tiles by using a multi-specification integrated mold, eliminating the need to change the mold and modify the glaze lines, thus reducing production costs. Simultaneously, pre-calculating the overall usage parameters avoids dimensional deviations caused by the separation of multiple specifications, thereby improving production efficiency.

[0085] It should be understood that the application of the present invention is not limited to the examples above. Those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

Claims

1. A method for integrated manufacturing of multi-specification ceramic tiles, characterized in that, The method includes: Determine the mold appearance dimensions, mold design gap dimensions, edge grinding control dimensions, cutting seam dimensions, and trimming seam dimensions corresponding to the multi-specification ceramic master bricks to be produced; Based on the mold's external dimensions, the mold's design gap dimensions, and the required ceramic tile specifications, a multi-specification integrated mold is designed and manufactured. The required blank is pressed using the multi-specification integrated mold, and the blank is processed into multi-specification ceramic master bricks based on the edge grinding control dimensions. Based on the cutting seam size and trimming seam size, the multi-specification ceramic mother brick is separated into ceramic bricks of various specifications.

2. The integrated manufacturing method for multi-specification ceramic tiles according to claim 1, characterized in that, Determine the mold appearance dimensions, mold design gap dimensions, edge grinding control dimensions, cutting seam dimensions, and trimming seam dimensions corresponding to the various specifications of ceramic master bricks to be produced, including: Determine the required water absorption rate of the ceramic tile, and determine the firing shrinkage rate based on the water absorption rate; Determine the mold's external dimensions, and then determine the green body drying dimensions based on the mold's external dimensions; The fired appearance dimensions are calculated based on the drying dimensions of the green body and the firing shrinkage rate, and the edge grinding control dimensions are determined based on the fired appearance dimensions. Obtain the preset tiling gap size, and calculate the mold design gap size based on the preset tiling gap size and the firing shrinkage rate; The cutting seam size is determined based on the preset tiling gap size, and the trimming seam size is calculated based on the preset tiling gap size and the cutting seam size.

3. The integrated manufacturing method for multi-specification ceramic tiles according to claim 2, characterized in that, The fired appearance size is the product of the difference obtained by subtracting the firing shrinkage rate and the dried size of the green body; the mold design gap size is the ratio of the preset laying gap size to the difference obtained by subtracting the firing shrinkage rate; The cutting seam size is less than or equal to the preset tiling gap size; the trimming seam size is half the difference between the preset tiling gap size and the cutting seam size.

4. The integrated manufacturing method for multi-specification ceramic tiles according to claim 1, characterized in that, Based on the mold's external dimensions, the mold's design gap dimensions, and the required ceramic tile specifications, a multi-specification integrated mold is designed and manufactured, including: Based on the mold's external dimensions, the mold's design gap size, and the required ceramic tile specifications, the layout is performed under the mold's external dimensions to obtain the divided mold sub-regions. Based on the divided mold sub-regions, multi-specification integrated molds are designed and manufactured. Each mold sub-region corresponds to a ceramic tile position, and there are mold design gap dimensions between each mold sub-region.

5. The integrated manufacturing method for multi-specification ceramic tiles according to claim 4, characterized in that, The multi-specification integrated mold has a decorative surface and a paving surface corresponding to each mold sub-area. The decorative surface has a predetermined effect edge, and the paving surface has a predetermined border.

6. The integrated manufacturing method for multi-specification ceramic tiles according to claim 2, characterized in that, The required blank is pressed using the multi-specification integrated mold, and the blank is processed into multi-specification ceramic master bricks based on the edge grinding control dimensions, including: The required blank is pressed using the multi-specification integrated mold, and the blank is processed into a fired ceramic brick with the appearance and size after firing according to the ceramic brick process flow. The fired ceramic bricks are edge-ground to obtain multi-specification ceramic master bricks with edge-ground control dimensions.

7. The integrated manufacturing method for multi-specification ceramic tiles according to claim 1, characterized in that, Based on the cutting seam size and trimming seam size, the multi-specification ceramic mother brick is separated into ceramic bricks of various specifications, including: Based on the cutting seam size, the ceramic bricks of each specification on the multi-specification ceramic mother brick are separated to obtain the separated ceramic bricks of each specification. Based on the trimming seam size, the separation edges of the separated ceramic tiles of each specification are trimmed to obtain trimmed ceramic tiles of each specification.

8. The integrated manufacturing method for multi-specification ceramic tiles according to claim 1, characterized in that, The multi-specification ceramic master brick has grooves between the ceramic bricks of different specifications to display the outline of each specification of ceramic brick.

9. The integrated manufacturing method for multi-specification ceramic tiles according to claim 1, characterized in that, Based on the cutting seam size and trimming seam size, after separating the multi-specification ceramic mother brick into ceramic bricks of various specifications, the process further includes: Ceramic tiles of various specifications are packaged and stored in the warehouse according to a single specification, or according to the proportion of ceramic tiles of various specifications in the predetermined combination paving scheme.

10. A ceramic tile, characterized in that, The ceramic tile is manufactured by the integrated manufacturing method for multi-specification ceramic tiles as described in any one of claims 1 to 9.

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