Dry Granular Glaze for Clear Ceramic Tile Surfaces
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Solution Overview
Problem
Traditional ceramic tile production methods result in uneven mirror surfaces and blurry pattern textures, making it difficult to achieve clear glaze effects, especially with dark layout designs, and are associated with high production costs and instability.
Innovation Solution
A wet slurry spraying process using a specific composition of dry granular frits with different melting points, combined with ink-jet printing and bell-shaped spraying, to produce ceramic tiles with a highly flat mirror surface and clear transparency, addressing the issues of pore formation and production complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional polished glaze and polished tile production methods are used, then production cost is reduced and process is simple, but the mirror surface becomes uneven and pattern texture becomes blurry
Solution Approach 1:
The glaze is segmented into multiple functional layers: a base glaze layer providing smoothness, and separate dry granular glaze particles containing printing powder for pattern formation. This segmentation allows each layer to perform its specific function independently, achieving clear patterns and flat surfaces without requiring complex production equipment.
Solution Approach 2:
The printing powder is preliminarily mixed with dry granular glaze particles before application to the green body. This preliminary preparation ensures that the pattern information is pre-encoded in the glaze material itself, allowing clear pattern textures to be formed during firing without requiring complex post-processing or specialized printing equipment.
2Object-generated harmful factors
If dry spreading process is adopted, then production cost increases and technology becomes complex, but pore formation increases on dark plate surfaces
Solution Approach 1:
The glaze composition parameters are changed by incorporating specific printing powder components (feldspar 45-50%, limestone 15-17%, quartz 35-40%) into the dry granular glaze. These parameter changes in material composition enable the glaze to form dense, pore-free surfaces on dark plates while maintaining a relatively simple bell-shaped spraying process.
Solution Approach 2:
The dry granular glaze is formulated as a composite material combining multiple components: dry granular frit (15-17%), printing powder (5-7%), and binder (35-38%). This composite formulation creates a glaze system that simultaneously achieves dark color saturation, surface density, and pattern clarity without requiring complex multi-step production technologies.
3Manufacturing precision
If dry granular glaze spraying is used, then clear glaze effect is achieved, but production technology becomes unstable
Solution Approach 1:
Different regions of the glaze system have different qualities: the base glaze provides uniform smoothness, while the dry granular particles with printing powder provide localized pattern formation. This local differentiation of functionality allows clear glaze effects and stable production, as each component performs its specific role reliably without requiring complex overall process control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process achieves a clear glaze effect with complex texture details, reduces pore formation on dark color layouts, and simplifies production, resulting in a more stable and cost-effective ceramic tile production method.
Implementation Method 1
bell-shaped spraying dry granular glaze
Implementation Method 2
sintering to obtain ceramic tiles
Implementation Method 3
the softening temperature of the dry granular frit A is 1135° C. to 1175° C., the softening temperature of the dry granular frit B is 980° C. to 1050° C., and the softening temperature of the dry granular frit C is 1020° C. to 1127° C.
Data Source
AI summary
A dry granular ceramic tile from a wet slurry spraying process and a preparation method thereof, comprises: applying an overglaze on a green body, applying a pattern by ink-jet printing, applying a dry granular glaze by bell-shaped spraying, and sintering to obtain ceramic tiles. The dry granular glaze contains: by mass percentage, dry granular frit A: 15%, dry granular frit B: 12% to 15%, dry granular frit C: 13% to 17%. The softening temperature of the dry granular frit A is 1135° C. to 1175° C., 980° C. to 1050° C. for the dry granular frit B, and 1020° C. to 1127° C. for the dry granular frit C. The dry granular frits used in the present invention adopts a combination of dry granular frits with three different melting points, and using such a matching method, it is convenient for the effective adjustment of the brick shape and the firing temperature during production.