A controllable brick-shaped green bottom spraying method, ceramic tile and preparation method thereof

Abstract

The application provides a brick-shaped controllable body bottom spraying method, a ceramic tile and a preparation method thereof. The brick-shaped controllable body bottom spraying method comprises the following steps: determining a deformation type between a body and a surface glaze layer of a required ceramic tile, determining a target body slip formula based on the deformation type; preparing the target body slip, spraying the target body slip on the bottom surface of the body of the required ceramic tile to obtain a body with sprayed body slip; processing the body with sprayed body slip into a target ceramic tile after firing, detecting the brick shape of the target ceramic tile to obtain a brick shape change amount; determining a target spraying amount of the target body slip based on the brick shape change amount of the target ceramic tile, and spraying the target body slip on the bottom surface of the body of the required ceramic tile according to the target spraying amount, so that the brick shape change amount of the ceramic tile with sprayed target body slip is within a predetermined standard range. The application adjusts the brick shape of the ceramic tile by spraying the body slip on the bottom surface of the ceramic tile, and efficiency and product quality are considered.

Description

Technical Field

[0001] This invention relates to the field of ceramic tile production technology, and in particular to a method for controlling the shape of the tile base by spraying, ceramic tiles and their preparation methods. Background Technology

[0002] With continuous innovation in the architectural ceramic tile industry and consumers' increasing demand for personalized products, the variety of tile products is becoming increasingly abundant, including fully polished glazed tiles, matte polished tiles, velvet tiles, and dry-granule tiles. While this provides consumers with more choices, it also necessitates providing more production platforms on the manufacturing side. To achieve specific glaze effects, such as the soft feel of velvet glaze or the non-slip finish of dry-granule tiles, the glaze formula needs to be adjusted accordingly. The greater the difference in the formula system, the greater the change in tile shape during firing. When the tile shape exceeds the standard range, it is often necessary to correct it by adjusting the kiln. As is well known, the continuity and stability of production in ceramic production are the foundation for ensuring production quality. Frequent platform changes have a significant impact on the continuity of production, especially the stability of tile shape. The straightness of the tile shape is one of the important quality indicators of the product.

[0003] The main methods for adjusting the shape of floor tiles include kiln adjustment, glaze formula adjustment, and body formula adjustment. Among these, adjusting the glaze and body formulas changes their expansion coefficients to adjust the tile shape. However, this method has drawbacks: body adjustment is time-consuming and cannot be quickly implemented for different product platforms; glaze formula adjustment, due to the need to balance decorative effect and avoid glaze defects, has limited adjustment range. Kiln adjustment is highly efficient and significant in adjusting tile shape, but it greatly affects the firing atmosphere, leading to significant color changes during firing and potentially causing product quality issues. In short, existing tile shape adjustment methods cannot balance efficiency and product quality.

[0004] Therefore, existing technologies have shortcomings and need to be improved and developed. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a method for controlling the shape of the brick base spraying, a ceramic brick and its preparation method, in order to solve the problem that the existing brick shape adjustment methods cannot balance efficiency and product quality.

[0006] The technical solution adopted by this invention to solve the technical problem is as follows: A method for spraying a brick-shaped blank base with controllable brick shape, wherein the method includes: Determine the type of deformation that occurs between the ceramic tile body and the glaze layer, and determine the target base slurry formula based on the deformation type; Prepare the target primer according to the target primer formula, and spray the target primer onto the bottom surface of the desired ceramic tile body according to the preset spraying amount to obtain a body with the primer sprayed on. The pre-coated blank is processed into a fired target ceramic brick, and the brick shape is tested to obtain the change in brick shape. The target spraying amount of the target primer is determined based on the shape change of the target ceramic tile. The target primer is then sprayed onto the bottom surface of the desired ceramic tile body according to the target spraying amount, so that the shape change of the ceramic tile sprayed with the target primer is within a predetermined standard range.

[0007] In one embodiment of this application, determining the type of deformation occurring between the body and the glaze layer of the desired ceramic tile, and determining the target base slurry formulation based on the deformation type, includes: Determine the type of deformation that occurs between the body and the glaze layer of the desired ceramic tile, including arching deformation and concave deformation; Obtain a pre-prepared first slurry formulation and a second slurry formulation. The first slurry prepared with the first slurry formulation has a first linear expansion coefficient after sintering that is greater than the linear expansion coefficient of the green body after sintering. The second slurry prepared with the second slurry formulation has a second linear expansion coefficient after sintering that is less than the linear expansion coefficient of the green body after sintering. The target slurry formulation is determined in the first and second slurry formulations based on the deformation type.

[0008] In one embodiment of this application, determining a target primer formulation based on the deformation type in the first primer formulation and the second primer formulation includes: If the deformation type is concave deformation, then the first base slurry formulation is used as the target base slurry formulation; If the deformation type is arch deformation, then the second base slurry formulation is used as the target base slurry formulation.

[0009] In one embodiment of this application, the absolute value of the difference between the first linear expansion coefficient and the linear expansion coefficient of the sintered billet is greater than or equal to 2 × 10⁻⁶. -6 / ℃; the absolute value of the difference between the second linear expansion coefficient and the linear expansion coefficient of the sintered billet is greater than or equal to 2×10 -6 / ℃.

[0010] In one embodiment of this application, the raw materials of the first base slurry formulation, by weight, include: Nepheline 80-90 parts, ball soil 3-10 parts, alumina 0-10 parts; The raw materials of the second base slurry formulation, by weight, include: 80-90 parts fused silica, 3-5 parts ball clay, and 0-15 parts flux and fluxing agent raw materials.

[0011] In one embodiment of this application, within a temperature range of 30°C to 400°C, the coefficient of linear expansion of the sintered green body is (6.0~8.5)×10⁻⁶. -6 The linear expansion coefficient of the nepheline is (30.0~31.0)×10. -6 The coefficient of linear expansion of the fused silica is (0.5~0.9)×10. -6 .

[0012] In one embodiment of this application, a target primer is prepared according to the target primer formulation, and the target primer is sprayed onto the bottom surface of the desired ceramic tile body according to a preset spraying amount to obtain a primer-coated body, comprising: Prepare the target primer according to the target primer formulation; Obtain multiple preset spray amounts according to a predetermined gradient, and spray the target primer onto the bottom surface of the desired ceramic tile body according to the multiple preset spray amounts to obtain a body with the primer sprayed on. The preset spraying amount is all between 50 and 500 g / m². 2 Within the range.

[0013] In one embodiment of this application, determining the target spraying amount of the target primer based on the change in the shape of the target ceramic tile includes: Determine the minimum value among the changes in brick shape corresponding to the target ceramic tile with each preset spray amount; The preset spraying amount corresponding to the minimum value is taken as the target spraying amount of the target primer.

[0014] This application also provides a method for preparing ceramic tiles, wherein the method for preparing ceramic tiles includes: Obtain a blank with the target primer sprayed on the bottom surface, obtained by the brick-shaped controllable blank bottom spraying method described above; The upper surface of the blank is decorated with printed patterns and glazed, and then fired in a kiln to obtain ceramic bricks.

[0015] This application also provides a ceramic tile, wherein the ceramic tile is prepared by the ceramic tile preparation method described above.

[0016] This invention provides a method for controlling the shape of a ceramic tile by spraying a base coat, a ceramic tile, and a method for preparing the same. The method includes: determining the type of deformation between the desired ceramic tile body and the glaze layer; determining a target base coat formula based on the deformation type; preparing a target base coat according to the target base coat formula; and spraying the target base coat onto the bottom surface of the desired ceramic tile body according to a preset spraying amount to obtain a base coat with the base coat; processing the base coat into a fired target ceramic tile; performing shape detection on the target ceramic tile to obtain the shape change; determining a target spraying amount of the target base coat based on the shape change of the target ceramic tile; and spraying the target base coat onto the bottom surface of the desired ceramic tile body according to the target spraying amount, so that the shape change of the ceramic tile with the target base coat is within a predetermined standard range. This application adjusts the shape of the ceramic tile by spraying a base coat onto the bottom surface of the ceramic tile, avoiding kiln adjustments, glaze formula adjustments, and body formula adjustments, thus balancing efficiency and product quality. Attached Figure Description

[0017] Figure 1 This is a flowchart of a preferred embodiment of the brick-shaped controllable blank bottom spraying method in this invention.

[0018] Figure 2 This is a schematic diagram of a preferred embodiment of the brick-shaped controllable blank bottom spraying method in this invention. Detailed Implementation

[0019] 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.

[0020] In existing technologies, the main methods for adjusting the shape of floor tiles include kiln adjustment, glaze formula adjustment, and body formula adjustment. Among these, glaze and body formula adjustments change the coefficient of expansion of the glaze and body materials, thereby adjusting the tile shape. However, their drawback is the long adjustment cycle for body materials, making rapid adjustments unsuitable for different product platforms. Glaze formula adjustments must consider both decorative effects and glaze defects such as pinholes, limiting the adjustment range. Kiln adjustment is highly efficient and significant in adjusting the tile shape, but it greatly affects the firing atmosphere, leading to significant color changes during firing and potentially causing product quality issues.

[0021] Based on the problems of the existing technology, this invention develops a bottom-coating process for ceramic tile blanks. This process involves spraying a coating with a specific coefficient of thermal expansion onto the lower surface of the tile blank. The traditional two-layer process of "glaze layer + blank layer" is adjusted to a three-layer process of "glaze layer + blank layer + bottom-coating layer." The amount of coating can be controlled according to production needs to adjust the overall size and shape of the tile. In ceramic tile production, the difference in the coefficient of thermal expansion between the glaze layer and the blank results in arching or concave deformation. When the coefficient of thermal expansion of the glaze layer is less than that of the blank layer, arching deformation occurs; conversely, concave deformation occurs. Similarly, spraying a coating layer with a coefficient of thermal expansion significantly different from that of the blank can control the tile shape. The coating layer uses both high-coefficient and low-coefficient slurry systems to facilitate adjustments to the range of deformation (arching or concave) for different types of tiles during platform transitions.

[0022] The following description, with reference to the accompanying drawings, illustrates a method for controlling the shape of a ceramic tile under a blank, a ceramic tile, and a method for preparing the same. Addressing the issue mentioned in the background art that the brick shape adjustment methods cannot simultaneously achieve efficiency and product quality, this application provides a method for controlling the shape of a ceramic tile under a blank. In this method, the deformation type between the desired ceramic tile blank and the glaze layer is determined, and a target base slurry formula is determined based on the deformation type. A target base slurry is prepared according to the target base slurry formula, and the target base slurry is sprayed onto the bottom surface of the desired ceramic tile blank according to a preset spraying amount, resulting in a blank with the base slurry sprayed. The blank with the base slurry sprayed is processed into a fired target ceramic tile, and the shape of the target ceramic tile is detected to obtain the change in shape. A target spraying amount of the target base slurry is determined based on the change in shape of the target ceramic tile, and the target base slurry is sprayed onto the bottom surface of the desired ceramic tile blank according to the target spraying amount, so that the change in shape of the ceramic tile sprayed with the target base slurry is within a predetermined standard range. This application adjusts the shape of ceramic tiles by spraying a base slurry onto the bottom surface of the ceramic tile, avoiding the drawbacks of kiln adjustments that cause large fluctuations in product quality, limited adjustments to glaze formulas, and long adjustment cycles for body formulas, thus balancing efficiency and product quality.

[0023] Please see Figure 1 , Figure 1 This is a flowchart of the brick-shaped controllable blank bottom spraying method in this invention. For example... Figure 1 As shown, the brick-shaped controllable blank bottom spraying method described in this embodiment of the invention includes: Step S100: Determine the type of deformation that occurs between the ceramic tile body and the glaze layer, and determine the target base slurry formula based on the deformation type.

[0024] In this embodiment of the application, step S100 specifically includes: Step S110: Determine the type of deformation that occurs between the body and the glaze layer of the desired ceramic tile. The deformation types include arching deformation and concave deformation. Step S120: Obtain the pre-prepared first slurry formula and second slurry formula. The first linear expansion coefficient of the first slurry prepared by the first slurry formula after sintering is greater than the linear expansion coefficient of the green body after sintering. The second linear expansion coefficient of the second slurry prepared by the second slurry formula after sintering is less than the linear expansion coefficient of the green body after sintering. Step S130: Determine the target slurry formulation in the first and second slurry formulations based on the deformation type.

[0025] Specifically, ceramic tiles consist of a body and a glaze. Both shrink during the firing process, but their shrinkage rates and expansion coefficients differ, which can easily generate internal stress at the interface, resulting in arching or concave deformation.

[0026] The arching or concave deformation in this application refers to the deformation of the glaze layer relative to the body, or the bending shape of the entire brick in the glaze direction. Arching deformation refers to the glaze layer of the ceramic brick bulging outward relative to the body, with the brick surface exhibiting an arc-shaped arch that is higher in the middle and lower at the edges, and the glaze layer as a whole exhibiting an outward arching deformation. Concave deformation refers to the glaze layer of the ceramic brick sinking inward relative to the body, with the brick surface exhibiting an arc-shaped sinking that is lower in the middle and higher at the edges, and the glaze layer as a whole exhibiting an inward concave deformation.

[0027] The coefficient of linear expansion, also known as the coefficient of linear thermal expansion, is a physical parameter characterizing the degree of linear dimensional expansion and contraction of a material as it is heated or cooled. It is commonly used to measure the thermal expansion and contraction characteristics of inorganic materials such as ceramic bodies and glazes. Physically, it represents the relative elongation per unit length of a material for every 1°C (or 1K) increase in temperature within a given temperature range. In ceramic tile systems, the difference in the coefficients of linear expansion between the body and the glaze layer is a major cause of defects such as interfacial stress, glaze arching, concave deformation, and glaze cracking.

[0028] In one embodiment of this application, step S130 specifically includes: Step S131: If the deformation type is concave deformation, then the first base slurry formulation is used as the target base slurry formulation; Step S132: If the deformation type is arch deformation, then the second base slurry formulation is used as the target base slurry formulation.

[0029] Specifically, when the brick exhibits concave deformation (i.e., the glaze layer on the upper surface of the brick is under tensile stress, causing the glaze layer to sink downwards along with the brick), this application sprays a slurry with a coefficient of linear expansion greater than that of the brick onto the bottom surface of the brick. Because the coefficient of linear expansion of the sprayed layer is greater than that of the brick, the sprayed layer shrinks more during cooling, resulting in tensile stress. This exerts an upward pulling force on the brick, causing the brick to convexly deform. This trend is opposite to the original concave deformation direction. Therefore, the upper and lower surfaces of the brick are subjected to mutually canceling forces, thereby adjusting the brick, which would have deformed concavely, back to a normal brick shape.

[0030] When the brick exhibits arch deformation (i.e., the glaze layer on the upper surface of the blank is under compressive stress, and the brick shape is arched upward relative to the glaze layer), this application sprays a slurry with a linear expansion coefficient smaller than that of the blank on the bottom surface of the blank. Since the linear expansion coefficient of the sprayed layer is smaller than that of the blank, the sprayed layer shrinks less during the cooling process and is subjected to compressive stress, thereby generating a downward pulling force on the blank, causing the brick to have a downward concave deformation tendency. This tendency is opposite to the original arch deformation direction. Therefore, the upper and lower surfaces of the blank are subjected to mutually canceling forces, thereby adjusting the brick that would originally arch to a normal brick shape.

[0031] In this embodiment, the absolute value of the difference between the first linear expansion coefficient and the linear expansion coefficient of the sintered billet is greater than or equal to 2 × 10⁻⁶. -6 / ℃; the absolute value of the difference between the second linear expansion coefficient and the linear expansion coefficient of the sintered billet is greater than or equal to 2×10 -6 / ℃.

[0032] Specifically, the difference in the expansion coefficients is expressed as: Δα = α 底浆 α 坯 To ensure the brick shape adjustment effect, the absolute value of the difference in expansion coefficients, |Δα|, should be controlled to be ≥2×10. -6 / ℃.

[0033] This application ensures the brick shape adjustment effect by controlling the difference between the first linear expansion coefficient, the second linear expansion coefficient and the linear expansion coefficient of the sintered green body.

[0034] In one embodiment of this application, the raw materials of the first base slurry formulation, by weight, include: Nepheline 80-90 parts, ball soil 3-10 parts, alumina 0-10 parts.

[0035] In this application, the formulation of the first base slurry uses nepheline and other raw materials with a high coefficient of expansion as the main raw materials, and adds an appropriate amount of clay to provide suspension and adhesion between the slurry and the green body during spraying. Since the free quartz contained in the green body has a high coefficient of expansion, the dissolution of free quartz by the sprayed layer during high-temperature firing should be minimized, and an appropriate amount of alumina is added to control the firing temperature.

[0036] The raw materials of the second base slurry formulation, by weight, include: 80-90 parts fused silica, 3-5 parts ball clay, and 0-15 parts flux and fluxing agent raw materials.

[0037] Fused silica is an amorphous form of silica formed by rapidly cooling high-purity silica raw materials such as quartz sand and crystal after melting at high temperatures (generally ≥1700℃). It belongs to the quartz glass category of materials.

[0038] In this application, the formulation system of the second base slurry uses fused silica raw material with a small coefficient of expansion as the main raw material, adds an appropriate amount of ball clay to provide suspension and adhesion between the slurry and the base during spraying, and adds an appropriate amount of flux and fluxing agent to improve the sintering degree of the formulation.

[0039] The first base slurry (large expansion coefficient base slurry) is used to adjust the shape of the product bricks in the direction of arch deformation, and the second base slurry (small expansion coefficient base slurry) is used to adjust the shape of the product bricks in the direction of concave deformation. The adjustment range of the brick shape is controlled by adjusting the amount of slurry sprayed.

[0040] Specifically, for the first and second base slurries, CMC (sodium carboxymethyl cellulose), sodium tripolyphosphate, and other auxiliary materials are added to the raw materials of the first and second base slurries for ball milling to a certain fineness. After iron removal, sieving, and aging, qualified first and second base slurries are obtained. The fineness is 0.3%~0.7% residue on a 325-mesh sieve. The milled glaze slurry is filtered through a 100-mesh double-layer sieve, and after passing through an iron removal tank, the glaze slurry is pumped to a slurry tank for aging to obtain the first and second base slurries.

[0041] This application is completely different from the traditional method of controlling brick shape by adjusting the kiln, glaze formula, and raw material formula. Instead, it adopts a bottom spraying process, which provides a new way to control the shape of floor tiles during the production process.

[0042] In this embodiment of the application, within a temperature range of 30°C to 400°C, the coefficient of linear expansion of the sintered green body is (6.0~8.5)×10⁻¹⁰. -6 The linear expansion coefficient of the nepheline is (30.0~31.0)×10. -6 The coefficient of linear expansion of the fused silica is (0.5~0.9)×10. -6 .

[0043] The main materials used in the first and second slurries and the linear expansion coefficients of the building ceramic blanks are shown in Table 1.

[0044] Table 1

[0045] In this application, the first base slurry, whose main component is nepheline, is a material with a high coefficient of expansion compared to the green body, while the second base slurry, whose main component is fused silica, is a material with a low coefficient of expansion compared to the green body. Thus, when the brick shape exceeds the quality control range due to a production platform change, the brick shape can be corrected by controlling the type and amount of slurry sprayed on the green body, while ensuring that the kiln and glaze remain unchanged.

[0046] Furthermore, the first and second primer formulations are not intended to limit this application. They mainly provide a spray coating with a large difference in expansion coefficient from the preform and can be adjusted according to actual effects and economic considerations.

[0047] like Figure 1 As shown in the embodiment of the present invention, the brick-shaped controllable blank bottom spraying method further includes: Step S200: Prepare the target primer according to the target primer formula, and spray the target primer onto the bottom surface of the desired ceramic tile body according to the preset spraying amount to obtain a body with the primer sprayed.

[0048] Specifically, a base slurry is evenly sprayed onto the lower surface of the blank using a glazing spraying device, and after drying, a coating layer is formed. The specific gravity of the sprayed base slurry is controlled at 1.30–1.40 g / ml, the Engler viscosity is controlled at 20–40 seconds, and the dry glaze amount is 50–500 g / ml. 2 The spray nozzle parameters are: orifice diameter 0.31mm, spray angle 110° wide angle, to ensure uniform spraying.

[0049] After firing, the expansion coefficient of the sprayed coating on the bottom of the ceramic tile differs significantly from that of the tile body, thus enabling the correction of ceramic tile products when platform transitions or tile shape fluctuations exceed the standard.

[0050] In this embodiment of the application, step S200 specifically includes: Step S210: Prepare the target primer according to the target primer formulation; Step S220: Obtain multiple preset spraying amounts according to a predetermined gradient, and spray the target base coat onto the bottom surface of the desired ceramic tile blank according to the multiple preset spraying amounts to obtain a blank with the base coat.

[0051] The preset spraying amount is all between 50 and 500 g / m². 2 Within the range.

[0052] In step S210, when preparing the target slurry, as follows: Figure 2 As shown, the base slurry is prepared according to the formula of the target base slurry, and then ball-milled, sieved, and iron-removed to obtain the target base slurry. The target base slurry is used to spray onto the bottom surface of a dried ceramic body.

[0053] Considering the actual moisture control of the kiln feed during production, the preset spraying amount is controlled between 50 and 500 g / m². 2 The spraying amount refers to the amount of dry glaze material sprayed, that is, the amount of dry material corresponding to the glaze slurry. Taking the thickness of a regular floor tile as an example, the reference values ​​for the difference in expansion coefficients, the amount of spraying slurry, and the corresponding changes in tile shape are shown in Table 2.

[0054] Table 2

[0055] This application involves spraying the base slurry onto the bottom of the blank, which has no impact on the glaze effect or the color of the glaze decorative pattern.

[0056] like Figure 1 As shown in the embodiment of the present invention, the brick-shaped controllable blank bottom spraying method further includes: Step S300: The green body with the sprayed primer is processed into the target ceramic brick after firing, and the brick shape is detected to obtain the change in brick shape.

[0057] Specifically, after the base coat is sprayed and dried, the ceramic tile undergoes conventional printing decoration and glazing before being fired at high temperature in a kiln. This application, except for the addition of a base coat spraying step, follows the same process and production steps as the conventional process. After exiting the kiln, the shape of the ceramic tile is inspected, and the amount of arching or concave deformation is measured.

[0058] like Figure 1 As shown in the embodiment of the present invention, the brick-shaped controllable blank bottom spraying method further includes: Step S400: Determine the target spraying amount of the target primer based on the brick shape change of the target ceramic tile, and spray the target primer onto the bottom surface of the required ceramic tile body according to the target spraying amount, so that the brick shape change of the ceramic tile sprayed with the target primer is within a predetermined standard range.

[0059] In this embodiment of the application, the step S400 of "determining the target spraying amount of the target primer based on the brick shape change of the target ceramic tile" specifically includes: determining the minimum value among the brick shape changes corresponding to the target ceramic tile with each preset spraying amount; and taking the preset spraying amount corresponding to the minimum value as the target spraying amount of the target primer.

[0060] This application allows for the control of the brick shape adjustment range by adjusting the type and amount of spray coating slurry according to production needs.

[0061] The following are specific examples for illustration.

[0062] Example 1: The production of 600*1200 matte polished floor tiles resulted in excessive arch deformation after switching to a fully polished glazed platform. The tile shape was corrected using a bottom-spraying process, without changing the raw material, glaze formula, or kiln firing.

[0063] For arch deformation exceeding the standard, a formula system with a small expansion coefficient is selected. The formula for the base slurry spray coating, by weight, includes: 80 parts fused silica, 5 parts ball soil, 7 parts calcined talc, and 8 parts potassium feldspar.

[0064] After obtaining qualified slurry through ball milling, the bottom surface of the green body is sprayed with the slurry and then processed into fired ceramic bricks. The shape of the ceramic bricks with different spraying amounts is measured, and the results are shown in Table 3.

[0065] Table 3

[0066] The above test results show that when the arch deformation exceeds the standard during platform conversion, the brick shape can be corrected by spraying a base slurry with a small expansion coefficient. When the formula remains unchanged, the amount of spraying layer can be adjusted to control the change in brick shape, so that the brick shape can be controlled.

[0067] Example 2: When producing 600*1200 matte polished floor tiles, excessive deformation occurred after switching to a dry-granule glaze platform. The tile shape was corrected using a bottom-spraying process, without changing the raw material, glaze formula, or kiln firing.

[0068] For excessive concave deformation, a high expansion coefficient formulation system is selected. The base slurry spray coating formulation, by weight, includes: 87 parts nepheline, 5 parts ball clay, and 8 parts alumina.

[0069] After obtaining qualified slurry through ball milling, the bottom surface of the green body is sprayed with the slurry and then processed into fired ceramic bricks. The shape of the ceramic bricks with different spraying amounts is measured, and the results are shown in Table 4.

[0070] Table 4

[0071] The above test results show that when the platform conversion results in excessive concave deformation, the brick shape can be corrected by spraying a base slurry with a large expansion coefficient. When the formula remains unchanged, the amount of spraying layer can be adjusted to control the change in brick shape, thus making the brick shape controllable.

[0072] This application achieves the following effects: First, this application allows for process adjustments to adjust the shape of ceramic tiles according to production needs, ensuring that the shape of the product tiles is controllable. Secondly, this application can control the type and amount of spray coating slurry to control the brick shape according to production needs, giving production great flexibility when changing platforms.

[0073] Third, the coating layer of this application is sprayed on the bottom of the blank, which has no effect on the glaze effect and the color of the glaze decorative pattern, thus ensuring the stability of production when adjusting the brick shape.

[0074] Fourth, this application does not require adjustments to the kiln and glaze during production platform conversion; only the spray coating needs to be adjusted, thus ensuring production continuity.

[0075] This application also provides a method for preparing ceramic tiles, wherein the method for preparing ceramic tiles includes: Obtain a blank with the target primer sprayed on the bottom surface based on the brick shape controllable bottom spraying method described above; The upper surface of the blank is decorated with printed patterns and glazed, and then fired in a kiln to obtain ceramic bricks.

[0076] Once the target slurry is determined, such as Figure 2 As shown, apart from adding the bottom spraying step, the other processes and production steps are the same as the conventional process. That is, the blank with the bottom sprayed is dried, decorated with patterns and glazed, dried, fired in the kiln, and polished / ground. There is no need to change the original process and parameters, which reduces production costs and improves production efficiency.

[0077] This application also provides a ceramic tile, which is prepared by the ceramic tile preparation method described above.

[0078] In summary, this invention discloses a method for controlling the shape of a ceramic tile under a blank, a ceramic tile, and a method for preparing the same. The method for controlling the shape of a ceramic tile under a blank includes: determining the type of deformation that occurs between the blank and the glaze layer of the desired ceramic tile; determining a target base slurry formula based on the deformation type; preparing a target base slurry according to the target base slurry formula; and spraying the target base slurry onto the bottom surface of the desired ceramic tile blank according to a preset spraying amount to obtain a blank with the base slurry applied; processing the blank with the base slurry applied into a fired target ceramic tile; performing a shape detection test on the target ceramic tile to obtain the shape change amount; determining a target spraying amount of the target base slurry based on the shape change amount of the target ceramic tile; and spraying the target base slurry onto the bottom surface of the desired ceramic tile blank according to the target spraying amount, so that the shape change amount of the ceramic tile with the target base slurry applied is within a predetermined standard range. This application adjusts the shape of ceramic tiles by spraying a base slurry onto the bottom surface of the ceramic tile, avoiding the need for kiln adjustments, glaze formula adjustments, and body material formula adjustments, thus balancing efficiency and product quality.

[0079] 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 spraying a controllable brick-shaped base, characterized in that, The brick-shaped controllable blank bottom spraying method includes: Determine the type of deformation that occurs between the ceramic tile body and the glaze layer, and determine the target base slurry formula based on the deformation type; Prepare the target primer according to the target primer formula, and spray the target primer onto the bottom surface of the desired ceramic tile body according to the preset spraying amount to obtain a body with the primer sprayed on. The pre-coated blank is processed into a fired target ceramic brick, and the brick shape is tested to obtain the change in brick shape. The target spraying amount of the target primer is determined based on the shape change of the target ceramic tile. The target primer is then sprayed onto the bottom surface of the desired ceramic tile body according to the target spraying amount, so that the shape change of the ceramic tile sprayed with the target primer is within a predetermined standard range.

2. The method for controlling the shape of the brick undercoat by spraying according to claim 1, characterized in that, Determine the type of deformation that occurs between the ceramic tile body and the glaze layer, and determine the target base slurry formulation based on the deformation type, including: Determine the type of deformation that occurs between the body and the glaze layer of the desired ceramic tile, including arching deformation and concave deformation; Obtain a pre-prepared first slurry formulation and a second slurry formulation. The first slurry prepared with the first slurry formulation has a first linear expansion coefficient after sintering that is greater than the linear expansion coefficient of the green body after sintering. The second slurry prepared with the second slurry formulation has a second linear expansion coefficient after sintering that is less than the linear expansion coefficient of the green body after sintering. The target slurry formulation is determined in the first and second slurry formulations based on the deformation type.

3. The method for controlling the shape of the brick undercoat spraying according to claim 2, characterized in that, Determining a target base slurry formulation based on the deformation type in the first and second base slurry formulations includes: If the deformation type is concave deformation, then the first base slurry formulation is used as the target base slurry formulation; If the deformation type is arch deformation, then the second base slurry formulation is used as the target base slurry formulation.

4. The method for controlling the shape of the brick undercoat by spraying according to claim 2, characterized in that, The absolute value of the difference between the first linear expansion coefficient and the linear expansion coefficient of the sintered green body is greater than or equal to 2 × 10⁻⁶. -6 / ℃; the absolute value of the difference between the second linear expansion coefficient and the linear expansion coefficient of the sintered billet is greater than or equal to 2×10 -6 / ℃.

5. The method for controlling the shape of the brick undercoat by spraying according to claim 2, characterized in that, The raw materials of the first base slurry formulation, by weight, include: Nepheline 80-90 parts, ball soil 3-10 parts, alumina 0-10 parts; The raw materials of the second base slurry formulation, by weight, include: 80-90 parts fused silica, 3-5 parts ball clay, and 0-15 parts flux and fluxing agent raw materials.

6. The method for controlling the shape of the brick undercoat by spraying according to claim 5, characterized in that, Within a temperature range of 30℃ to 400℃, the coefficient of linear expansion of the sintered green body is (6.0~8.5)×10⁻¹⁰. -6 The linear expansion coefficient of the nepheline is (30.0~31.0)×10. -6 The coefficient of linear expansion of the fused silica is (0.5~0.9)×10. -6 .

7. The method for controlling the shape of the brick undercoat by spraying according to claim 1, characterized in that, Prepare the target primer according to the target primer formula, and spray the target primer onto the bottom surface of the desired ceramic tile body according to the preset spraying amount, to obtain a body with the primer sprayed on, including: Prepare the target primer according to the target primer formulation; Multiple preset spraying amounts are set according to a predetermined gradient. The target primer is sprayed onto the bottom surface of the desired ceramic tile body according to the multiple preset spraying amounts to obtain a body with the primer sprayed on. The preset spraying amount is all between 50 and 500 g / m². 2 Within the range.

8. The method for controlling the shape of the brick undercoat by spraying according to claim 1, characterized in that, The target spraying amount of the target primer is determined based on the change in the shape of the target ceramic tile, including: Determine the minimum value among the changes in brick shape corresponding to the target ceramic tile with each preset spray amount; The preset spraying amount corresponding to the minimum value is taken as the target spraying amount of the target primer.

9. A method for preparing ceramic bricks, characterized in that, The method for preparing ceramic bricks includes: Obtain a blank with the target primer sprayed on the bottom surface, obtained by the brick-shaped controllable blank bottom spraying method as described in any one of claims 1 to 8; The upper surface of the blank is decorated with printed patterns and glazed, and then fired in a kiln to obtain ceramic bricks.

10. A ceramic tile, characterized in that, The ceramic brick is prepared by the ceramic brick preparation method as described in claim 9.

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