A volcanic rock-imitated matte ceramic tile and a preparation method thereof

Abstract

The present application belongs to the field of building ceramics, and particularly relates to a kind of matte volcanic rock imitating ceramic tile and a preparation method thereof.The preparation method of the present application comprises the following steps: preparing body powder and expanded perlite particles, reverse punching, drying into a green body, applying a glaze layer, printing color ink, applying white positioning dry particles or transparent positioning dry particles, applying dry particle protective glaze, firing, brushing, edge grinding, and sorting.The preparation method of the present application breaks through the depth and form limitations of traditional digital molds by introducing expanded perlite material, and further uses a multi-layer glaze firing and glue dry particle composite process to precisely construct a three-dimensional relief structure and a cave groove effect with rich levels, random depth and lightness on the tile surface, with a natural and smooth touch, and a texture direction that can be controlled according to design requirements, achieving a dual simulation from vision to touch, while ensuring the stability of industrial mass production, with a yield of more than 97%.

Description

Technical Field

[0001] This invention relates to the field of building ceramics, and in particular to a matte ceramic tile that mimics volcanic rock and its preparation method. Background Technology

[0002] In the building materials industry, various types of ceramic tiles are frequently used. Depending on the application scenario and aesthetic value, different processes and functional properties are applied to the glaze of ceramic tiles. Glaze effects can be categorized into polished, antique, marble, and embossed textured finishes. Polished, marble, and antique finishes are already commonplace, while embossed textured finishes are a rising star, increasingly popular among contemporary consumers. They can mimic the textured surface of natural stone, offering a return to simplicity and authenticity.

[0003] In order to make products more realistic like natural stone, the contemporary ceramic tile industry has continuously updated and iterated its production technology and equipment. The development process has applied processes such as steel mold pressing, embossed glaze printing, replica fine carving ink, digital molds, and positioning glue dry granules to achieve the texture of surface relief, making the glaze of ceramic tiles closer and closer to the texture of stone. Currently, the most popular stone surface finishes on the market are polished, with a variety of niche raised finishes. Ceramic tile glaze finishes, on the other hand, involve pressing ceramic tile powder into raised textures using steel molds, printing different performance glazes onto the surface of the tile body, or using a digital inkjet printer to position and print adhesive, then applying and stacking dry granules to create raised textures. These techniques primarily create various types and shapes of raised textures on the ceramic tile surface, rarely capturing the natural grooves and cave textures of stone. Recently, a new generation of digital mold-effect surfaces has been developed, involving the spraying of deep ink into specific areas, followed by a layer of glaze. Utilizing the oil-water separation principle of the ink, the water-based glaze sprayed onto the surface is repelled, creating shallow grooves and a recessed, peeling texture, resulting in a new generation of raised textured products. However, the peeling effect is relatively shallow, the groove lines are narrow, the depth is insufficient, the texture is not natural enough, and the resemblance to natural stone is low. Volcanic rocks and travertine natural stones have natural striped textures and granular cave textures with obvious and deep grooves, which current industry production processes cannot meet due to their shallow groove textures. Summary of the Invention

[0004] To address the aforementioned issues, this invention selects suitable materials with shrinkage properties that have undergone high-temperature firing, processes the raw materials, and combines them with a glaze layer process to produce matte ceramic tiles that mimic volcanic rock. These tiles feature controllable variations in groove depth and length, adjustable and controllable groove edge feel and texture direction, and a cave effect, significantly enhancing their similarity to volcanic rock and travertine-like natural stones.

[0005] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A method for preparing a matte ceramic tile that mimics volcanic rock includes the following steps: Step 1: Prepare the green body powder and expanded perlite granules; Step 2: First, apply the expanded perlite particles to the bottom of the blank mold according to the design pattern, then fill the blank powder, scrape it flat, and press it into a blank. After pressing, flip the blank so that the side with the expanded perlite particles is facing up. Step 3: Dry the blank obtained in step 2 to form a raw blank; Step 4: Apply a glaze layer to the surface of the unglazed body obtained in Step 3; Step 5: Print with colored ink to print the pre-designed volcanic rock pattern onto the surface of the brick blank obtained in Step 4; Step 6: Apply white or transparent positioning dry granules to the surface of the brick blank obtained in step 5 according to the set relief effect; Step 7: Apply dry granule protective glaze to the surface of the brick blank obtained in step 6; Step 8: Fire the brick blanks obtained in Step 7; Step 9: Brush, polish, grind, and sort the brick blanks obtained in Step 8 to obtain the imitation volcanic rock matte ceramic bricks.

[0006] This invention introduces expanded perlite particles to create desired cave-like groove textures at the bottom of the ceramic tile mold. Combined with digital mold textures, this allows for a wider variety of groove sizes, textures, and cave effects, significantly enhancing the realism of ceramic tiles and natural stone. Furthermore, during the material application process, expanded perlite particles are first applied. These particles are lightweight, and their slight impact on the mold surface causes a slight positional shift. Next, ceramic tile powder particles are applied, creating a secondary slight impact on the particles, causing minor changes in their position and shape. After pressing and resetting, the tiles are flipped so that the perlite particle side faces upwards. Each tile exhibits slight positional changes in the particles, resulting in a consistent overall shape of the cave-like grooves after firing, yet with diverse details, ensuring no two tiles are identical and creating a vivid and natural tiling effect. Additionally, particles of different shapes and sizes can be randomly scattered on the tile surface to create unarranged cave-like groove textures, further enriching the natural and varied patterns.

[0007] Preferably, the expanded perlite particles are expanded perlite particles modified with a hardener to improve the surface hardening degree of the expanded perlite, increase the surface compressive strength of the expanded perlite particles, and avoid insufficient support during pressing and molding, resulting in deformation of the shape. More preferably, the hardener includes at least one of water glass, silicon phosphate, potassium methylsilicate waterproof hardener, and lithium-based penetrating hardener.

[0008] Preferably, the expanded perlite particles have a particle size of 2-10mm. If the expanded perlite particles are too small, the groove effect will not be achieved, and they will be easily misjudged as defects. If the particles are too large, the brick blank will not be compacted enough, which will reduce the strength of the brick blank.

[0009] Preferably, in step 3, the drying temperature of the blank is 100-200℃ and the drying time is 60-90min.

[0010] Preferably, in step 4, a water-based glaze is first applied to the surface of the unglazed body obtained in step 3 to form a first glaze layer; then, an oil-based replica ink is applied to the first glaze layer to form a replica ink layer; finally, the water-based glaze is applied to the replica ink layer to form a replica glaze layer. That is, the glaze layer sequentially includes a first glaze layer, a replica ink layer, and a replica glaze layer. The ink in the replica ink layer is oil-based, while the glazes in the first and replica glaze layers are both water-based. The contact between oil-based and water-based substances causes mutual repulsion, resulting in oil-water separation. This leads to peeling between the water-based glaze layer and the oil-based ink layer, forming a shallow groove texture following the ink pattern, creating a replica effect and better achieving the imitation volcanic rock effect.

[0011] More preferably, the specific gravity of the water-based glaze is 1.45-1.55 g / mL, and the glaze application amount is 300-520 g / mL. 2 .

[0012] Preferably, in step 6, the application rate of the white or transparent positioning dry granules is 100-300 g / m³. 2 .

[0013] Preferably, in step 7, the dry granule protective glaze comprises, by weight, 20-32 parts of GL2208F25 dry granules, 5-10 parts of GL1926F20 dry granules, and 30-40 parts of 9022A suspending agent.

[0014] Preferably, in step 8, the firing temperature is 1180-1220℃ and the firing time is 65-80min.

[0015] In another aspect, the present invention also provides a matte ceramic brick with volcanic rock finish prepared by the above-described preparation method.

[0016] Compared with the prior art, the present invention has the following beneficial effects: 1) The preparation method of the present invention introduces expanded perlite particles into the blank as a groove forming material. When the expanded perlite is calcined at a high temperature of 1200℃, its volume will shrink drastically to one-tenth to one-twentieth of its original size. At the location where the perlite filling particles are, obvious cavities and grooves with the same shape as the particles will be left. Moreover, the main component of perlite is silicon dioxide, which forms a strong three-dimensional shape of the cavities and grooves, which is realistic and natural, just like a natural formation.

[0017] 2) The preparation method of this invention forms a cave-like groove texture with the desired direction in the fabric of the brick body. When used in conjunction with the digital mold texture, the groove texture can vary in size and coarseness, and also has a cave effect. Moreover, according to the texture requirements, particles of different shapes and sizes can be randomly sprinkled on the surface of the brick body powder fabric layer. After firing, a cave-like groove texture without the need for arrangement is formed, with rich and diverse variations, which greatly improves the realism of ceramic bricks and natural stone.

[0018] 3) In the preparation method of this invention, expanded perlite granules are first laid out when the blank is laid out. The granules are relatively light and have a slight impact on the contact surface of the mold when the filling granules are laid out, causing a slight positional shift. Then, blank powder granules are laid out. The blank powder granules cause a second slight impact on the filling granules, and the position and shape of the filling granules will change slightly. After being pressed and reversed, the blank is flipped by a brick blank flipping device so that the side with perlite granules faces up. The filling granules on the surface of each brick blank will have a slight positional change. After firing, the shape of the karst grooves formed is consistent overall, but the details are varied. Each brick is unique, and the product laying effect is vivid and natural.

[0019] 4) The preparation method of this invention selects suitable materials with shrinkage properties after high-temperature firing, selects raw materials for processing, and combines glaze layer technology to prepare imitation volcanic rock matte ceramic tiles. The resulting tiles have controllable groove depth and groove length variations, adjustable and controllable groove edge feel and texture direction, strong three-dimensionality of the karst groove shape, realistic and natural appearance, as if naturally formed, and excellent wear resistance, modulus of rupture, and stain resistance. Attached Figure Description

[0020] Figure 1 This is a close-up image of the actual object of the press reverse pressing of the blank in Embodiment 1 of the present invention; Figure 2 This is a close-up view of the ceramic brick after firing according to Embodiment 1 of the present invention. Detailed Implementation

[0021] The present invention is further illustrated by the following embodiments. It should be understood that the following embodiments are for illustrative purposes only and are not intended to limit the present invention.

[0022] Unless otherwise specified, the experimental methods used in the following embodiments are conventional methods, and the experimental materials used in the following embodiments are all available through conventional commercial channels.

[0023] Raw material source description: GL2208F25 and GL1926F20 dry granules: Anhui Pansheng New Material Technology Co., Ltd. 9022A Suspension Agent: Jiangxi Qiantao New Material Co., Ltd.

[0024] Unless otherwise specified, all quantities mentioned in the embodiments of the present invention are by weight.

[0025] This invention provides a method for preparing matte ceramic tiles that mimic volcanic rock, comprising the following steps: Step 1: Prepare the green body powder and expanded perlite granules.

[0026] The green body powder can be a conventional green body powder. By controlling the particle size distribution and the moisture content to 6.7-7.6 wt%, it can be easily pressed into shape.

[0027] In one specific embodiment, the green body powder may include: 10-20 parts potassium silicate powder, 10-20 parts kaolin, 12-25 parts sodium silicate powder, 5-10 parts black mud, 5-15 parts Huzhen clay, 5-10 parts Huaiji clay, 15-25 parts potassium-sodium sand, and 3-8 parts polishing clay. The chemical composition of the green body powder, by mass percentage, includes: 66.78% SiO2, 19.43% Al2O3, 0.61% Fe2O3, 0.26% TiO2, 0.64% CaO, 0.95% MgO, 3.62% K2O, 2.75% Na2O, and 4.96% loss on ignition.

[0028] Expanded perlite, primarily composed of silica, is incorporated into the brick body. The perlite is distributed according to the grooves and textures of the designed pattern. After high-temperature firing, its volume shrinks dramatically to 1 / 10-1 / 20 of its original size. This leaves distinct, naturally shaped cavity grooves where perlite particles are present, creating a strong three-dimensional effect. Preferably, the expanded perlite particles have a diameter of 2-10mm. Particles that are too small will not produce the desired groove effect and may be mistaken for defects. Particles that are too large will result in insufficient compaction of the brick body, reducing its strength. In a preferred embodiment, appropriately sized expanded perlite particles can be selected using a water-based method. During water selection, broken expanded perlite particles settle to the bottom, along with impurities and dust. The remaining pure, intact expanded perlite particles can be collected on the surface, ensuring the desired groove and cavity effect after subsequent sintering.

[0029] Since the green body needs to be pressed during the formation process, in order to improve the surface compressive strength of the expanded perlite particles and avoid insufficient support during pressing and deformation, expanded perlite particles modified with a hardener are used in some preferred embodiments. The hardener includes at least one of water glass, silicon phosphate, potassium methylsilicate waterproof hardener, and lithium-based penetrating hardener. For example, in some preferred embodiments, the hardener is composed of water glass and potassium methylsilicate in a weight ratio of 1:1.

[0030] In some preferred embodiments, the expanded perlite particles are surface-hardened by immersing them in an aqueous solution containing a hardener. The surface of expanded perlite has many micropores; the hardener solution penetrates the perlite surface, coating and modifying it. The hardener reacts with the silicon-oxygen bonds on the expanded perlite surface, forming a hard, glassy crystalline shell after drying, increasing the particle hardness. Simultaneously, it becomes hydrophobic and wear-resistant, giving the expanded perlite particles excellent mechanical strength and weather resistance. Preferably, the weight ratio of hardener to water in the solution is 1:(20-30). Preferably, the immersion time is 5-20 minutes. If the immersion time is too short, the surface strength of the modified expanded perlite particles is low, resulting in low compressive strength during pressing, causing deformation, volume reduction, and indistinct cavities after firing, which can easily be misjudged as defects. Conversely, if the immersion time is too long, the modified expanded perlite particles are too hard, resulting in excessively deep cavities after firing, and decreased flexural strength. After natural immersion, drying is performed to obtain the hardened and modified expanded perlite particles. Preferably, the drying temperature is 100-200℃.

[0031] Step 2: First, apply the expanded perlite particles to the bottom of the blank mold according to the design pattern, then fill the blank powder, scrape it flat, press it into a blank, and then flip the pressed blank so that the side with the expanded perlite particles is facing up.

[0032] In this step, the brick blank is made using a reverse-firing mode. First, expanded perlite granules are laid out. The granules are relatively light, and when they are filled, they have a slight impact on the contact surface with the mold, causing a slight positional shift. Then, the brick blank powder granules are laid out. During the laying process, the powder will cause a secondary slight impact on the expanded perlite granules, and the position and shape of the expanded perlite granules will change slightly. After reverse-firing and pressing, the brick blank is flipped so that the side with expanded perlite granules faces upward. The granules on the surface of each brick blank will have a slight positional change. After firing, the shape of the karst grooves formed is consistent overall, but the details are varied and unique. Each brick is different, and the product paving effect is more vivid and natural.

[0033] Step 3: Dry the blank obtained in step 2 into a raw blank.

[0034] This step mainly involves drying the green body to give it a certain strength, making it easier to apply glaze later. In some preferred embodiments, the green body is dried at a temperature of 100-200℃ for 60-90 minutes.

[0035] Step 4: Apply a glaze layer to the surface of the unglazed body obtained in step 3.

[0036] In this step, applying a glaze layer to the surface of the unglazed blank improves the effect of the formed grooves and pits, while also providing protection. In a preferred embodiment, a water-based glaze is first applied to the surface of the unglazed blank obtained in step 3 to form a first glaze layer; then, a replica ink is applied to the first glaze layer to form a replica ink layer; finally, the water-based glaze is applied to the replica ink layer to form a replica glaze layer. That is, the glaze layer sequentially includes a first glaze layer, a replica ink layer, and a replica glaze layer. The ink in the replica ink layer is oil-based, while the glazes in the first and replica glaze layers are both water-based. The contact between oil-based and water-based substances creates a repulsive effect, resulting in oil-water separation. Therefore, peeling occurs between the water-based glaze layer and the oil-based ink layer, forming a shallow groove texture following the ink pattern, creating a replica texture and better achieving the effect of a simulated volcanic rock surface.

[0037] In some specific embodiments, the raw materials used in the water-based glaze are proportioned as follows: 22 parts potassium feldspar, 15 parts sodium feldspar, 8 parts kaolin, 10 parts calcined clay, 7 parts spinel, 8 parts diopside, 9 parts wollastonite, 11 parts calcined talc, 3 parts zinc oxide, and 7 parts zirconium silicate. When using, the materials are prepared according to the above proportions, then water is added and the mixture is ball-milled to obtain the glaze slurry. Preferably, the specific gravity of the water-based glaze is 1.45-1.55 g / mL, and the glaze application rate is 300-520 g / mL. 2 .

[0038] Water-based glazes can be applied by spraying or dipping, with spraying being the preferred method. Sprayed glazes have a high water content, good fluidity, good adhesion between the body and the glaze, a uniform and smooth glaze surface, and clearer groove contours after firing, resulting in a stronger three-dimensional effect and a defect-free surface.

[0039] For replica ink, any commercially available replica ink can be used, and it can be applied via inkjet printing.

[0040] Step 5: Print with colored ink and print the pre-designed volcanic rock design onto the brick blank obtained in step 4.

[0041] In this step, various colored inks are printed according to the set volcanic rock pattern, and grooves and caves are used to better simulate the effect of volcanic rock.

[0042] Step 6: Apply white or transparent positioning dry granules to the brick blank obtained in step 5 according to the set relief effect.

[0043] Specifically, a design rendering of the raised positioning positions can be set first. A digital inkjet printer is then used to print the positioning adhesive according to the design. White or transparent positioning granules are then applied using a granule applicator. Excess granules are collected by a granule recycling system, leaving the positioning granules at the digital adhesive positions, thus creating the raised effect. In a preferred embodiment, the application amount of the white or transparent positioning granules is 100-300 g / m². 2 .

[0044] Step 7: Apply dry granule protective glaze to the brick blank obtained in step 6.

[0045] Specifically, a dry-granule protective glaze can be applied by spraying. In a preferred embodiment, the specific gravity of the dry-granule protective glaze is 1.20-1.35 g / mL, and the application amount is 150-240 g / mL. 2 .

[0046] In a preferred embodiment, the dry granule protective glaze comprises, by weight, 20-32 parts of GL2208F25 dry granules, 5-10 parts of GL1926F20 dry granules, and 30-40 parts of 9022A suspending agent.

[0047] Step 8: Fire the brick blanks obtained in Step 7.

[0048] In a preferred embodiment, the firing temperature is 1180-1220℃ and the firing time is 65-80 minutes.

[0049] Step 9: Brush, polish, grind, and sort the brick blanks obtained in Step 8 to obtain the imitation volcanic rock matte ceramic bricks.

[0050] The following detailed description, in conjunction with specific embodiments, will further illustrate this point.

[0051] Example 1 This embodiment provides a matte ceramic tile that mimics volcanic rock, the preparation method of which includes the following steps: (1) Preparation of modified expanded perlite, including the following steps: S1. The expanded perlite ore is crushed into particles of different sizes, and then the particle size distribution is screened by a double vibrating screen. After multi-layer vibrating screening, expanded perlite particles with a particle size of 5mm are selected for use. S2. The expanded perlite particles screened in step S1 are put into a sedimentation tank filled with flowing water and washed and stirred for 8 minutes. The expanded perlite particles float on the surface of the flowing water, while the impurities and dust from the crushing process settle in the sedimentation tank. The expanded perlite particles that flow out of the sedimentation tank with the water are collected to obtain primary expanded perlite particles. S3. The primary expanded perlite particles collected in step S2 are transported to a drying oven at 150°C and dried for 15 minutes before being released to obtain surface-dried primary expanded perlite particles. S4. Preparation of hardener solution: The hardener and water are prepared by weight ratio of hardener to water = 1:20. The hardener is composed of water glass and potassium methylsilicate in a weight ratio of 1:1. S5. Soak and stir the expanded perlite particles obtained in step S3 in the hardener solution obtained in step S4 for 10 minutes. S6. Filter out the water, and dry the expanded perlite particles soaked in the hardener in step S5 in a drying oven at 150°C for 15 minutes to obtain modified expanded perlite particles for later use.

[0052] (2) Preparation of body powder: According to the proportion of each raw material, potassium stone powder: 15 parts, kaolin: 16 parts, sodium stone powder: 18 parts, black mud: 8 parts, Huzhen mud: 10 parts, Huaiji mud: 8 parts, potassium sodium sand: 20 parts, polishing mud: 5 parts, ceramic brick body powder is prepared with a moisture content of 7.2wt%.

[0053] (3) Blank pressing: Using the reverse pressing mode, select the shape and size of the modified perlite particles obtained in step (1) according to the design pattern, apply dot-shaped or line-shaped modified expanded perlite particles in the required position in the press mold groove, then apply the brick blank powder obtained in step (2) in the mold frame where the expanded perlite particles have been applied and perform scraping treatment, press into the required size brick blank, and after pressing, flip the brick blank so that the side with the modified expanded perlite particles applied is facing up. Figure 1 A close-up image of a blank being pressed by a reverse press.

[0054] (4) The pressed brick blanks in step (3) are dried in a drying kiln at 150℃ for 80 minutes to obtain the raw brick blanks.

[0055] (5) The surface of the unglazed blank obtained in step (4) is sprayed with glaze to form the first glaze layer, with a specific gravity of 1.52 g / mL and an application amount of 420 g / mL. 2 .

[0056] The surface glaze used is made by ball milling 22 parts potassium feldspar, 15 parts sodium feldspar, 8 parts kaolin, 10 parts calcined clay, 7 parts spinel, 8 parts diopside, 9 parts wollastonite, 11 parts calcined talc, 3 parts zinc oxide, and 7 parts zirconium silicate with water.

[0057] (6) The first glaze layer formed in step (5) is printed with oil-based ink by digital inkjet printer, and the digital groove texture is printed on the surface of the brick blank according to the design, forming a replica ink layer.

[0058] (7) A replica surface glaze layer is formed on the surface of the replica ink layer formed in step (6) by spraying a glaze onto the surface of the replica ink layer. The specific gravity is 1.52 g / mL and the glaze application amount is 480 g / mL. 2 The surface glaze is the same as the glaze in step (4).

[0059] (8) The surface of the brick blank obtained in step (7) is printed with conventional color ink using a digital inkjet printer to print the set volcanic rock design on the brick blank.

[0060] (9) Positioning and embossing effect: Set the design effect drawing of the positioning and embossing position, and use a digital inkjet printer to print positioning adhesive on the surface of the brick blank obtained in step (8) according to the set design drawing. Apply white dry granules with a dry granule applicator at a rate of 200g / m². 2 Excess dry granules are recovered by the dry granule recovery system, leaving positioning dry granules at the digital glue position to create a raised effect.

[0061] (10) Spray dry granule protective glaze on the surface of the brick blank obtained in step (9): the specific gravity of the dry granule protective glaze is 1.30 g / mL, and the glaze application amount is 200 g / m. 2 The dry granule protective glaze was prepared by mixing 25 parts of GL2208F25 dry granules, 10 parts of GL1926F20 dry granules, and 35 parts of 9022A suspending agent evenly.

[0062] (11) Firing into semi-finished products: The brick blanks obtained in step (10) are fired in a roller kiln at a firing temperature of 1210℃ and a firing cycle of 70 minutes.

[0063] (12) The semi-finished products obtained in step (11) are brushed, polished, ground, sorted, packaged and stored.

[0064] Example 2 Referring to Example 1, the difference is that in step (1) S1, expanded perlite particles with a particle size of 3 mm are selected for modification, while the other steps and parameters remain unchanged.

[0065] Example 3 Referring to Example 1, the difference is that in step (1) S5, the expanded perlite is soaked in the hardener solution for 5 minutes, while the other steps and parameters remain unchanged.

[0066] Example 4 Referring to Example 1, the difference lies in step (10), where a spray glaze booth is used to spray dry granule protective glaze, the specific gravity of the dry granule protective glaze is adjusted to 1.35 g / mL, and the glaze application amount is 240 g / mL. 2 The remaining steps and parameters remain unchanged.

[0067] Comparative Example 1 Referring to Example 1, the difference is in step (3), where the surface of the pressed brick blank is not filled with modified expanded perlite filler particles, but only brick blank powder is used, while the other steps and parameters remain unchanged.

[0068] Comparative Example 2 Referring to Example 1, the difference lies in step (3), where the modified expanded perlite filling particles on the surface of the pressed brick blank are replaced with ordinary foam particles, while the remaining steps and parameters remain unchanged.

[0069] Comparative Example 3 Referring to Example 1, the difference lies in step (3), where the modified expanded perlite filling particles on the surface of the pressed brick blank are replaced with transparent frit particles, while the remaining steps and parameters remain unchanged.

[0070] Comparative Example 4 Referring to Example 1, the difference lies in step (5), where the application method and process parameters of the first glaze layer are changed, while the remaining steps and parameters remain unchanged.

[0071] Specifically, in steps (5) and (4), the surface of the unglazed body obtained in step (4) is coated with a water-based glaze using a glazing machine to form the first glaze layer, with a specific gravity of 1.86 g / mL and a glaze application rate of 420 g / mL. 2 .

[0072] The surface glaze used is made by ball milling 22 parts potassium feldspar, 15 parts sodium feldspar, 8 parts kaolin, 10 parts calcined clay, 7 parts spinel, 8 parts diopside, 9 parts wollastonite, 11 parts calcined talc, 3 parts zinc oxide, and 7 parts zirconium silicate with water.

[0073] The simulated volcanic rock ceramic bricks prepared in the above embodiments and comparative examples were tested respectively, and the test methods are as follows: Groove effect: Observe whether the surface effect of the ceramic tile has grooves. Figure 2 The effect of the cave grooves, the brightness of the bottom of the cave grooves, the strong light reflection and the oily gloss effect are oily, the non-reflective is matte, and whether there are different color changes and obvious defects at the location of the filling particles on the blank. Groove depth: According to GB / T 21388-2008 "Vernier, Dial and Digital Depth Calipers", at the location where the filling particles are placed on the green body, the depth value from the bottom of the groove to the level of the ceramic tile surface is measured with the depth gauge of the vernier caliper and marked as the groove depth, in mm; Abrasion resistance test: The abrasion resistance of the fired sample bricks was tested in accordance with GB / T 3810.7-2016 "Test methods for ceramic tiles - Part 7: Determination of abrasion resistance of glazed tile surfaces"; Modulus of rupture: The modulus of rupture of the fired brick samples was tested in accordance with GB / T 3810.4-2016 "Test methods for ceramic tiles - Part 4: Determination of modulus of rupture and breaking strength". Stain resistance: The stain resistance of the fired brick samples was tested in accordance with GB / T 3810.14-2016 "Test Methods for Ceramic Tiles - Part 14: Determination of Stain Resistance".

[0074] Based on the test results, the results were summarized and analyzed from several aspects, including groove effect, groove depth, wear resistance, modulus of rupture, and stain resistance, as shown in Table 1.

[0075] Table 1 Test results of Examples 1-4 and Comparative Examples 1-4 The surface effect of the ceramic tile prepared in Example 1 is as follows: Figure 2 As shown, the groove effect is obvious, with a depth of 0.8mm, and the product's wear resistance, modulus of rupture, and stain resistance meet the requirements. In Example 2, the expanded perlite particles selected have a smaller particle size than those in Example 1, resulting in a slightly reduced groove depth, but the product still meets the application requirements. In Example 3, the soaking time of the hardener solution is shorter than in Example 1, leading to low surface strength of the modified expanded perlite particles. When applied in the press, the particles have low compressive strength, resulting in compression deformation and volume reduction. After firing, the cavities are slightly shallower, and the edges are smooth, but the overall performance still meets the usage requirements. In Example 4, the specific gravity and amount of dry granule protective glaze are increased compared to Example 1, resulting in a corresponding improvement in the wear resistance and stain resistance of the glaze surface.

[0076] In Comparative Example 1, no filler particles were used, resulting in a smooth surface after firing without any cave effect, and the realism compared to natural stone was poor. In Comparative Example 2, ordinary foam filler particles were used. During pressing, the foam particles lacked support, and no obvious cave effect was formed after firing. Furthermore, the organic filler caused yellowing after firing, affecting the aesthetics. In Comparative Example 3, transparent frit particles were used as filler particles. Due to the low temperature of the transparent frit, the frit filler particles were fired at a low temperature, melting into a glassy substance, resulting in a noticeably glossy glaze. The gloss is high, which is inconsistent with the effect of natural stone, and the volume does not change significantly after melting, so the effect of the karst groove is not obvious. In Comparative Example 4, the method of applying the first glaze layer was changed to a glazing method. The glaze has a high specific gravity and poor fluidity, and cannot be well integrated with the filling particles. There are slight pinholes in the unintegrated areas. In contrast, the first glaze layer in Example 1 is a spray glaze with high water content and good fluidity. The body and the glaze have good bonding, the glaze surface is uniform and flat, the fired groove outline is clear, the three-dimensional effect is strong, and the surface is free of defects.

[0077] By comparing and testing Examples 1-4 and Comparative Examples 1-4, the particle size of the expanded perlite filler, the soaking time of the hardener solution, the specific gravity of the protective glaze, and the amount of dry glaze applied were adjusted. Based on Example 4, the surface cavity groove effect and wear resistance and stain resistance were further optimized, and the example tests were conducted.

[0078] Example 5 Referring to Example 1, the difference lies in steps S1 and S5 of step (1), where the particle size of the expanded perlite particles and the soaking and stirring time of the expanded perlite particles in the hardener solution are increased, while the remaining steps and parameters remain unchanged. Specifically: S1. The expanded perlite ore is crushed into particles of different sizes, and then the particle size distribution is screened by a double vibrating screen. After multi-layer vibrating screening, expanded perlite particles with a particle size of 8mm are selected for use. S5. Soak and stir the expanded perlite particles obtained in step S3 in the hardener solution obtained in step S4 for 15 minutes.

[0079] Example 6 Referring to Example 1, the difference lies in step (10), where the formulation ratio of the dry granule protective glaze and its application process parameters are changed, while the remaining steps and parameters remain unchanged. Specifically: Step (10) Spray dry granule protective glaze on the surface of the brick blank obtained in step (9): the specific gravity of the dry granule protective glaze is 1.33 g / mL, and the glaze application amount is 240 g / m². 2 The dry granule protective glaze formulation is as follows: GL2208F25 dry granules: 30 parts, GL1926F20 dry granules: 6 parts, 9022A suspending agent: 34 parts.

[0080] Example 7 Referring to Example 1, the difference lies in steps S1 and S5 and step (10) of step (1), where the particle size of the expanded perlite particles is increased, and the soaking and stirring time of the expanded perlite particles in the hardener solution is changed, and the formulation ratio of the dry granule protective glaze and its application process parameters are altered, while the remaining steps and parameters remain unchanged. Specifically: S1. The expanded perlite ore is crushed into particles of different sizes, and then the particle size distribution is screened by a double vibrating screen. After multi-layer vibrating screening, expanded perlite particles with a particle size of 8mm are selected for use. S5. Soak and stir the expanded perlite particles obtained in step S3 in the hardener solution obtained in step S4 for 15 minutes.

[0081] Step (10) Spray dry granule protective glaze on the surface of the brick blank obtained in step (9): the specific gravity of the dry granule protective glaze is 1.33 g / mL, and the glaze application amount is 240 g / m². 2 The dry granule protective glaze formulation is as follows: GL2208F25 dry granules: 30 parts, GL1926F20 dry granules: 6 parts, 9022A suspending agent: 34 parts.

[0082] The ceramic tiles obtained in Examples 5-7 were tested respectively, and the results were summarized and analyzed from several aspects such as groove effect, groove depth, modulus of rupture, and stain resistance, as shown in Table 2.

[0083] Table 2 Test Results of Examples 5-7 The test results of Example 5 show that larger expanded perlite filler particles and longer hardening agent soaking time result in better hardness of the modified expanded perlite filler particles. This leads to higher compressive strength during pressing of the green body, better preservation of the original shape, and a better effect of the cave-like grooves after firing. Example 6, by improving the dry-granule protective glaze ratio and process parameters, can enhance the glaze's wear resistance and stain resistance. In comparison, Example 7 shows the best overall effect, demonstrating superior cave-like groove texture, gloss, glaze wear resistance, and stain resistance. After adjustment, small variations in the cave-like grooves have little impact on the modulus of rupture of the ceramic tile. Using modified expanded perlite filler particles arranged on the surface of the green body creates a realistic volcanic rock-like glaze effect after firing, improving upon existing digital mold effects. The shallower groove texture enhances the realistic stone texture of the cave-like grooves on the surface of the volcanic rock ceramic tile.

[0084] In summary, the preparation method of this application not only breaks through the limitations of the depth and shape of traditional digital mold grooves by introducing modified expanded perlite materials, but also precisely constructs a rich, layered, and staggered three-dimensional relief structure and cave effect on the brick surface through multi-layer glaze firing and dry granule adhesive composite process; the texture is warm and natural to the touch, and the direction of the texture can be directionally controlled according to design requirements, achieving dual realism from visual to tactile. Moreover, the ceramic brick has good wear resistance, stain resistance and modulus of rupture, meeting the usage requirements; at the same time, the preparation method of this invention also takes into account the stability of industrial mass production, and the yield can be increased to over 97%.

[0085] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0086] The above-described embodiments are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, applying them to ceramic tile products with other design textures and patterns, or those with cave-like groove effects; these all fall within the protection scope of the present invention. Therefore, the protection scope of this invention patent should be determined by the appended claims.

Claims

1. A method for preparing a matte ceramic tile resembling volcanic rock, characterized in that, Includes the following steps: Step 1: Prepare the green body powder and expanded perlite granules; Step 2: First, apply the expanded perlite particles to the bottom of the blank mold according to the design pattern, then fill the blank powder, scrape it flat, and press it into a blank. After pressing, flip the blank so that the side with the expanded perlite particles is facing up. Step 3: Dry the blank obtained in Step 2 into a raw blank; Step 4: Apply a glaze layer to the surface of the unglazed body obtained in Step 3; Step 5: Print with colored ink to print the pre-designed volcanic rock pattern onto the surface of the brick blank obtained in Step 4; Step 6: Apply white or transparent positioning dry granules to the surface of the brick blank obtained in step 5 according to the set relief effect; Step 7: Apply dry granule protective glaze to the surface of the brick blank obtained in step 6; Step 8: Fire the brick blanks obtained in Step 7; Step 9: Brush, polish, grind, and sort the brick blanks obtained in Step 8 to obtain the imitation volcanic rock matte ceramic bricks.

2. The preparation method according to claim 1, characterized in that, In step 1, the expanded perlite particles are expanded perlite particles modified with a hardener. And / or, the expanded perlite particles have a particle size of 2-10 mm.

3. The preparation method according to claim 2, characterized in that, The hardener includes at least one of water glass, silicon phosphate, potassium methylsilicate waterproof hardener, and lithium-based penetrating hardener.

4. The preparation method according to claim 1, characterized in that, In step 3, the drying temperature of the blank is 100-200℃ and the drying time is 60-90min.

5. The preparation method according to claim 1, characterized in that, Step 4 includes the following steps: applying a water-based surface glaze to the surface of the unglazed body obtained in step 3 to form a first surface glaze layer; then applying an oil-based replica ink to the first surface glaze layer to form a replica ink layer; and finally applying the water-based surface glaze to the replica ink layer to form a replica surface glaze layer.

6. The preparation method according to claim 5, characterized in that, The specific gravity of the water-based glaze is 1.45-1.55 g / mL, and the glaze application rate is 300-520 g / mL. 2 .

7. The preparation method according to claim 1, characterized in that, In step 6, the application rate of the white or transparent positioning dry granules is 100-300 g / m³. 2 .

8. The preparation method according to claim 1, characterized in that, In step 7, the dry granule protective glaze comprises, by weight, 20-32 parts of GL2208F25 dry granules, 5-10 parts of GL1926F20 dry granules, and 30-40 parts of 9022A suspending agent.

9. The preparation method according to claim 1, characterized in that, In step 8, the firing temperature is 1180-1220℃ and the firing time is 65-80 minutes.

10. A matte ceramic tile imitating volcanic rock, characterized in that, It is prepared by the preparation method described in any one of claims 1-9.

Images