Method for manufacturing 3D stereoscopic super-white crystalline fully polished tile

Abstract

The application relates to the technical field of full-polished brick manufacturing, in particular to a manufacturing method of 3D stereoscopic super-white crystalline full-polished brick, which solves the problem that the glaze surface of the existing full-polished brick cannot be subjected to multilayer processing in the manufacturing process, thereby affecting the use effect of the glaze surface, and the glaze surface is prone to pinhole phenomenon, and comprises a base body and a composite glaze surface; the base body and the composite glaze surface are formed into 3D stereoscopic super-white crystalline full-polished brick through two-stage sintering; the composite glaze surface is located on the upper surface of the base body; the base body comprises 60% high-viscosity white clay, 20-28% quartz sand, 12-20% potassium feldspar and 3-6% zirconium silicate in terms of weight parts. The glaze surface of the full-polished brick is subjected to composite multilayer processing, the use effect of the glaze surface can be effectively improved, the crystalline glaze composition is accurately adjusted according to the expansion coefficient of the base body, and pinholes and cracks of the glaze surface are avoided.

Description

Technical Field

[0001] This invention relates to the field of fully polished brick manufacturing technology, specifically a method for manufacturing 3D three-dimensional ultra-white crystalline fully polished bricks. Background Technology

[0002] Fully polished tiles, also known as fully polished glazed ceramic tiles, are made with a special glaze formula that allows for polishing the glaze surface. It's the final glaze applied to antique-style tiles, typically a transparent glaze or a transparent embossed glaze. Fully polished glazed tiles combine the advantages of both polished and antique-style tiles. Ceramic tiles are widely used in engineering projects and home decoration as a primary building decoration material. The glaze surface of fully polished glazed ceramic tiles is as smooth and bright as polished tiles, while their glaze patterns are as rich and varied as those of antique-style tiles, with deep or vibrant colors.

[0003] Existing fully polished tiles cannot achieve multi-layer glaze treatment during the manufacturing process, which affects the performance of the glaze and makes the glaze prone to pinholes. Therefore, they do not meet the current requirements. In response, we have proposed a manufacturing method for 3D three-dimensional ultra-white crystalline fully polished tiles. Summary of the Invention

[0004] The purpose of this invention is to provide a manufacturing method for 3D ultra-white crystalline fully polished tiles, in order to solve the problem mentioned in the background art that existing fully polished tiles cannot achieve multi-layer glaze treatment during the manufacturing process, thus affecting the performance of the glaze and causing pinholes in the glaze.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a 3D three-dimensional ultra-white crystalline fully polished brick, comprising a basic body and a composite glaze, wherein the basic body and the composite glaze are formed into a 3D three-dimensional ultra-white crystalline fully polished brick by two-stage sintering. The composite glaze is located on the upper surface of the basic body. By weight, the basic body comprises 60% high-viscosity white clay, 20-28% quartz sand, 12-20% potassium feldspar, and 3-6% zirconium silicate. The composite glaze consists of a base glaze layer, a decorative layer, and a crystalline glaze layer, which are arranged sequentially from bottom to top. The base glaze layer is in close contact with the basic body.

[0006] Preferably, the base glaze layer comprises 55-60% SiO2, 12-15% Al2O3 and 8-12% ZrSiO4 by weight.

[0007] Preferably, the decorative layer is composed of a pigment and a nano-colloid, wherein the pigment is either an Fe-based pigment or a Cr-based pigment, and the pigment and nano-colloid are formed into the decorative layer by digital inkjet printing.

[0008] Preferably, by weight, the crystalline glaze layer contains 40-45% SiO2, 15-20% ZnO, 4-8% TiO2, 3-5% nucleating agent and 0.5%-1% carboxymethyl cellulose, wherein the nucleating agent is one of Cr2O3 and MnO2.

[0009] The manufacturing method of 3D ultra-white crystalline polished tiles includes the following steps: S1: Basic preform preparation. The basic preform ingredients are prepared by removing iron impurities using a fully automatic iron removal machine. Then, they are fed into a ball mill according to the mass ratio. The ball mill is used for ball milling and sieving through a vibrating screen to maintain the fineness of the slurry after sieving at ≤325 mesh and the moisture content at 32-35%. The slurry is then spray-dried to reduce the moisture content to 5-7%. The preform is pressed and shaped using a molding machine under ≥35 MPa conditions and then slowly heated and dried at 120-180℃. S2: The base glaze layer and the crystalline glaze layer are prepared separately. SiO2, Al2O3 and ZrSiO4 are mixed in a certain mass ratio to form the base glaze layer. SiO2, ZnO, TiO2, nucleating agent and carboxymethyl cellulose are mixed in a certain mass ratio to form the crystalline glaze layer. Temperature-sensitive polymer microspheres are added to the crystalline glaze layer. S3: Glaze coating. First, the base glaze layer is applied to the surface of the base body by mechanical spraying and then dried by infrared drying. After the base glaze layer has dried initially, the colorant and nano-colloid are printed into a three-dimensional texture on the surface of the base glaze layer by digital inkjet printing. Finally, the crystalline glaze layer is applied to the surface of the decorative layer in three layers by electrostatic spraying. S4: One-piece sintering molding, the base body with composite glaze is placed in the sintering furnace, and the fully polished brick is sintered twice. Before it is taken out of the furnace, the moisture content of the fully polished brick is kept to be reduced to below 1%. S5: Surface treatment and quality inspection. The surface of the fully polished bricks is polished using a polishing machine with a diamond grinding head under the protection of nano-cerium oxide polishing liquid. Then, a high-definition glazing machine is used to spray polyurethane coating on the surface of the fully polished bricks, and a wear-resistant layer is formed after curing. Finally, the whiteness, reflectivity and flexural strength of the fully polished bricks are measured using a colorimeter and a laser flatness tester.

[0010] Preferably, the thicknesses of the base glaze layer, decorative layer, and crystalline glaze layer are 0.2-0.3 mm, 0.05-0.1 mm, and 0.3-0.5 mm, respectively, and the electrostatic spraying particle size of the crystalline glaze layer is 5-10 μm.

[0011] Preferably, the two sintering temperatures of the fully polished brick are 1050-1190℃ and 1020℃, respectively.

[0012] Preferably, the thickness of the polyurethane coating is 0.1-0.3 mm, the grit size of the diamond grinding head is #800-#3000, the Mohs hardness of the fully polished brick is 6-7, and the water absorption rate is <0.1%.

[0013] Compared with the prior art, the beneficial effects of the present invention are: This invention improves the performance of fully polished bricks by performing a multi-layer composite treatment on the glaze surface. The addition of carboxymethyl cellulose avoids the occurrence of pinholes in the glaze due to excessive ZnO in the crystalline glaze. Temperature-sensitive polymer microspheres are added to the crystalline glaze layer to achieve non-uniform distribution of the nucleating agent in the glaze surface. At the same time, the composition of the crystalline glaze is precisely adjusted according to the body expansion coefficient to prevent cracking of the glaze surface. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a flowchart of the entire invention. Detailed Implementation

[0015] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0016] Please see Figure 1 The present invention provides an embodiment of a 3D three-dimensional ultra-white crystalline fully polished brick, comprising a base body and a composite glaze. The base body and the composite glaze are formed into a 3D three-dimensional ultra-white crystalline fully polished brick through a two-stage sintering process. The composite glaze is located on the upper surface of the base body. By weight, the base body comprises 60% high-viscosity white clay, 20-28% quartz sand, 12-20% potassium feldspar and 3-6% zirconium silicate. By controlling the amount of high-viscosity white clay used, it is easy to maintain the whiteness of the fully polished brick. The composite glaze consists of a base glaze layer, a decorative layer, and a crystalline glaze layer, arranged sequentially from bottom to top. The base glaze layer is in close contact with the base body. By weight, the base glaze layer comprises 55-60% SiO2, 12-15% Al2O3, and 8-12% ZrSiO4. The decorative layer consists of colorants and nano-colloids. The colorants are either Fe-based or Cr-based colorants. The colorants and nano-colloids are formed into the decorative layer by digital inkjet printing. By weight, the crystalline glaze layer comprises 40-45% SiO2, 15-20% ZnO, 4-8% TiO2, 3-5% nucleating agent, and 0.5%-1% carboxymethyl cellulose. The nucleating agent is either Cr2O3 or MnO2. The addition of carboxymethyl cellulose can prevent the occurrence of pinholes in the glaze due to excessive ZnO in the crystalline glaze.

[0017] Please see Figure 2 The manufacturing method of 3D ultra-white crystalline polished tiles includes the following steps: S1: Basic preform preparation. The basic preform ingredients are prepared by removing iron impurities using a fully automatic iron removal machine. Then, they are fed into a ball mill according to the mass ratio. The ball mill is used for ball milling and sieving through a vibrating screen to maintain the fineness of the slurry after sieving at ≤325 mesh and the moisture content at 32-35%. The slurry is then spray-dried to reduce the moisture content to 5-7%. The preform is pressed and shaped using a molding machine under ≥35 MPa conditions and then slowly heated and dried at 120-180℃. S2: The base glaze layer and the crystalline glaze layer are prepared separately. SiO2, Al2O3 and ZrSiO4 are mixed in a certain mass ratio to form the base glaze layer. SiO2, ZnO, TiO2, nucleating agent and carboxymethyl cellulose are mixed in a certain mass ratio to form the crystalline glaze layer. Temperature-sensitive polymer microspheres are added to the crystalline glaze layer. S3: Glaze coating. First, the base glaze layer is applied to the surface of the base body by mechanical spraying and then dried by infrared drying. After the base glaze layer has dried initially, the colorant and nano-colloid are printed into a three-dimensional texture on the surface of the base glaze layer by digital inkjet printing. Finally, the crystalline glaze layer is applied to the surface of the decorative layer in three layers by electrostatic spraying. S4: One-piece sintering molding, the base body with composite glaze is placed in the sintering furnace, and the fully polished brick is sintered twice. Before it is taken out of the furnace, the moisture content of the fully polished brick is kept to be reduced to below 1%. S5: Surface treatment and quality inspection. The surface of the fully polished bricks is polished using a polishing machine with a diamond grinding head under the protection of nano-cerium oxide polishing liquid. Then, a high-definition glazing machine is used to spray polyurethane coating on the surface of the fully polished bricks, and a wear-resistant layer is formed after curing. Finally, the whiteness, reflectivity and flexural strength of the fully polished bricks are measured using a colorimeter and a laser flatness tester.

[0018] The thicknesses of the base glaze layer, decorative layer, and crystalline glaze layer are 0.2-0.3 mm, 0.05-0.1 mm, and 0.3-0.5 mm, respectively. The electrostatic spraying particle size of the crystalline glaze layer is 5-10 μm. The two sintering temperatures of the fully polished brick are 1050-1190℃ and 1020℃, respectively. The two sintering processes can reduce lattice defects in the fully polished brick.

[0019] Furthermore, the thickness of the polyurethane coating is 0.1-0.3mm, the grit size of the diamond grinding head is #800-#3000, the Mohs hardness of the fully polished brick is 6-7, and the water absorption rate is <0.1%. By inspecting the parameters of the fully polished brick, the quality of the finished product is guaranteed.

[0020] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. 3D stereoscopic super-white crystalline fully polished tile comprising a base body and a composite glaze, characterized in that: The basic body and composite glaze are sintered in two stages to form a 3D three-dimensional ultra-white crystalline fully polished brick. The composite glaze is located on the upper surface of the basic body. By weight, the basic body includes 60% high-viscosity white clay, 20-28% quartz sand, 12-20% potassium feldspar and 3-6% zirconium silicate. The composite glaze consists of a base glaze layer, a decorative layer and a crystalline glaze layer, which are arranged sequentially from bottom to top. The base glaze layer is in close contact with the basic body.

2. The 3D stereoscopic ultra-white crystalline fully polished brick according to claim 1, characterized in that: By weight, the base glaze layer comprises 55-60% SiO2, 12-15% Al2O3 and 8-12% ZrSiO4.

3. The 3D stereoscopic ultra-white crystalline fully polished brick according to claim 2, characterized in that: The decorative layer is composed of pigments and nanocolloids. The pigments are either Fe-based or Cr-based pigments. The pigments and nanocolloids are formed into the decorative layer by digital inkjet printing.

4. The 3D stereoscopic ultra-white crystalline fully polished brick according to claim 3, characterized in that: By weight, the crystalline glaze layer contains 40-45% SiO2, 15-20% ZnO, 4-8% TiO2, 3-5% nucleating agent and 0.5%-1% carboxymethyl cellulose, wherein the nucleating agent is one of Cr2O3 and MnO2. 5.3D three-dimensional ultra-white crystalline fully polished brick manufacturing method, according to claim 4, characterized in that, Includes the following steps: S1: Basic preform preparation. The basic preform ingredients are prepared by removing iron impurities using a fully automatic iron removal machine. Then, they are fed into a ball mill according to the mass ratio. The ball mill is used for ball milling and sieving through a vibrating screen to maintain the fineness of the slurry after sieving at ≤325 mesh and the moisture content at 32-35%. The slurry is then spray-dried to reduce the moisture content to 5-7%. The preform is pressed and shaped using a molding machine under ≥35 MPa conditions and then slowly heated and dried at 120-180℃. S2: The base glaze layer and the crystalline glaze layer are prepared separately. SiO2, Al2O3 and ZrSiO4 are mixed in a certain mass ratio to form the base glaze layer. SiO2, ZnO, TiO2, nucleating agent and carboxymethyl cellulose are mixed in a certain mass ratio to form the crystalline glaze layer. Temperature-sensitive polymer microspheres are added to the crystalline glaze layer. S3: Glaze coating. First, the base glaze layer is applied to the surface of the base body by mechanical spraying and then dried by infrared drying. After the base glaze layer has dried initially, the colorant and nano-colloid are printed into a three-dimensional texture on the surface of the base glaze layer by digital inkjet printing. Finally, the crystalline glaze layer is applied to the surface of the decorative layer in three layers by electrostatic spraying. S4: One-piece sintering molding, the base body with composite glaze is placed in the sintering furnace, and the fully polished brick is sintered twice. Before it is taken out of the furnace, the moisture content of the fully polished brick is kept to be reduced to below 1%. S5: Surface treatment and quality inspection. The surface of the fully polished bricks is polished using a polishing machine with a diamond grinding head under the protection of nano-cerium oxide polishing liquid. Then, a high-definition glazing machine is used to spray polyurethane coating on the surface of the fully polished bricks, and a wear-resistant layer is formed after curing. Finally, the whiteness, reflectivity and flexural strength of the fully polished bricks are measured using a colorimeter and a laser flatness tester.

6. The manufacturing method of 3D three-dimensional ultra-white crystalline fully polished brick according to claim 5, characterized in that: The thicknesses of the base glaze layer, decorative layer, and crystalline glaze layer are 0.2-0.3 mm, 0.05-0.1 mm, and 0.3-0.5 mm, respectively, and the electrostatic spraying particle size of the crystalline glaze layer is 5-10 μm.

7. The manufacturing method of 3D three-dimensional ultra-white crystalline fully polished brick according to claim 5, characterized in that: The two sintering temperatures of the fully blasted bricks are 1050-1190℃ and 1020℃, respectively.

8. The manufacturing method of 3D three-dimensional ultra-white crystalline fully polished brick according to claim 5, characterized in that: The thickness of the polyurethane coating is 0.1-0.3 mm, the grit size of the diamond grinding head is #800-#3000, the Mohs hardness of the fully polished brick is 6-7, and the water absorption rate is <0.1%.

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