CN107935387B

CN107935387B - Colorful flaky dry particle glaze, flaky dry particle glaze cloth stone-like brick and preparation method thereof

Info

Publication number: CN107935387B
Application number: CN201711130828.9A
Authority: CN
Inventors: 萧礼标; 杨元东; 赵勇; 闫振华; 黄玲艳
Original assignee: Monalisa Group Co Ltd
Current assignee: Monalisa Group Co Ltd
Priority date: 2017-11-15
Filing date: 2017-11-15
Publication date: 2021-06-11
Anticipated expiration: 2037-11-15
Also published as: CN107935387A

Abstract

The invention relates to colorful flaky dry particle glaze, a flaky dry particle glaze cloth stone-like brick and a preparation method thereof. The preparation method of the colorful flaky dry particle glaze comprises the following steps: mixing glaze slips with different colors into colorful glaze slip, spraying the colorful glaze slip into a tray, drying to obtain a colorful mud slip layer, crushing the colorful mud slip layer, and sieving to obtain colorful flaky dry granular glaze. The colorful flaky dry particle glaze can be obtained through a simple process, can be used for preparing ceramic tiles, and can obtain stone-like products with vivid patterns, rich layers, natural textures, strong stereoscopic impression and granular sensation.

Description

Colorful flaky dry particle glaze, flaky dry particle glaze cloth stone-like brick and preparation method thereof

Technical Field

The invention relates to colorful flaky dry particle glaze, a flaky dry particle glaze cloth stone-like brick and a preparation method thereof, belonging to the technical field of production and manufacturing of ceramic bricks.

Background

The ceramic glaze is an indispensable raw material for ceramic manufacture, and has a very important influence on the performance and quality of the ceramic product. The existing ceramic frits can be roughly classified into the following according to categories and uses: lead glaze and lead-free glaze; raw glaze and fritted glaze; glaze for primary firing or secondary firing; glaze for ceramic tiles, tableware, sanitary ceramics and electroceramics; high-temperature glaze and low-temperature glaze; high expansion glaze and low expansion glaze; colored glaze and colorless glaze; transparent glaze and opaque glaze; glossy glaze, matte glaze, semi-matte glaze or patterned glaze and functional glaze: such as fluorescent glaze, metallic glaze, crystalline glaze, dry grain glaze, etc. The current dry grain glaze is a hot new product in industrial production and research, the product has rich patterns and rich levels, has the effects of matte, wear resistance, skid resistance and pollution resistance, and is praised as a new era for creating ceramic tile production technology.

Reference 1 (application No. 201610196097.7) discloses a method for producing a natural stone texture-imitated tile, comprising: adding a ceramic pigment into the ceramic blank to obtain color slurry, wherein the color slurry can also contain colored dry particles; the slurry is spread on the green brick to form a pattern layer, and then fired. The wet glaze making process has single decoration effect on ceramic tiles and is difficult to realize the effect of imitating natural stone.

Disclosure of Invention

Aiming at the problems, the invention aims to provide a preparation method of colorful flaky dry particle glaze, a stone-like product with vivid patterns, rich layers, natural textures, strong stereoscopic impression and granular impression and a preparation method thereof.

The application provides a preparation method of colorful flaky dry particle glaze on one hand, which is characterized by comprising the following steps:

mixing glaze slips with different colors into colorful glaze slip, spraying the colorful glaze slip into a tray, drying to obtain a colorful mud slip layer, crushing the colorful mud slip layer, and sieving to obtain colorful flaky dry granular glaze.

According to the invention, the colorful flaky dry particle glaze can be obtained through a simple process, and can be used for preparing ceramic tiles, so that stone-like products with vivid patterns, rich layers, natural textures, strong stereoscopic impression and strong granular sensation can be obtained.

Preferably, the specific gravity of the glaze slip is 1.60-1.80.

Preferably, the colorful glaze slurry is poured into the tray with a thickness of 1-2 mm.

Preferably, the drying temperature is 80-100 ℃, the drying time is 30-40 minutes, and the water content of the obtained colorful slurry layer after drying is lower than 1%.

Preferably, the granules below 2 meshes and above 8 meshes are taken as colorful flaky dry granule glaze during sieving.

Another aspect of the present application provides a method for preparing a stone-like tile with a sheet-like dry glaze cloth, comprising the following steps:

(1) preparing colorful flaky dry particle glaze according to any one of the preparation methods;

(2) the colorful flaky dry particle glaze is distributed on the blank according to the existing pattern in layers;

(3) after distributing, pre-pressing into green bricks with certain strength for the first time;

(4) spraying and printing a design pattern on the green brick by using an ink jet machine;

(5) pressing the green brick again;

(6) and sintering the obtained green bricks.

According to the invention, the colorful flaky dry particle glaze and the powder dry particle glaze are distributed in layers in advance and are molded into a green brick, and then the dry particle distribution and the ink-jet printing are combined by combining the ink-jet printing technology, so that the stone-like effect with randomly changed patterns, vividness, rich layers, natural textures, strong three-dimensional effect and granular sensation can be obtained.

Preferably, in the step (2), the colorful flaky dry particle glaze and the powder dry particle glaze are mixed and then distributed on the blank according to the existing pattern in layers. Preferably, the dry particle glaze of the powder is powder prepared from glaze materials with the same or different temperature formulas and colors.

Preferably, the grain composition of the powder dry grain glaze is as follows: 30-60 meshes: 30-37.5 wt%, 60-80 mesh: 42.5-50 wt%, 80-100 mesh: 12.5-17.5 wt%, 100 mesh: less than or equal to 5wt percent.

Preferably, in the step (2), the formula of the blank is as follows: SiO by weight₂：60～67％、Al₂O₃：19～23％、Fe₂O₃：0.5～1.0％、TiO₂：0.15～0.30％、CaO：0.4～0.7％、MgO：0.3～0.8％、K₂O：2.5～3.5％、Na₂O: 2.7-3.5%, loss on ignition: 4.5 to 5.5 percent. In the blank formula, the content of alumina is properly increased, the high-temperature deformation resistance of the blank is enhanced, the expansion coefficient of the blank is reduced, the difference of the expansion coefficients of the blank and the glaze is reduced, the adaptability of the blank glaze is improved, and the control of the shape of bricks fired by a kiln is facilitated.

Preferably, in the step (1), the dry glaze powder particles are powder prepared from glaze materials with the same or different temperature formulas and colors.

Preferably, the cloth pattern in the step (2) and the inkjet pattern in the step (4) are coordinated with each other to form a natural stone effect. The flaky dry grain glaze cloth has rough patterns and fine ink-jet patterns, the patterns are mutually associated and have complementary artistry and are carefully matched, the natural fusion of the effects of the cloth patterns and the ink-jet patterns is ensured, the grain effect of the natural stone is like the grain of the natural stone, and the grain effect of the natural stone is perfectly reproduced.

Preferably, in the step (2), a multi-machine-position carving roller is adopted to positively beat the secondary material distribution method for material distribution. Therefore, multi-layer cloth can be better realized. The secondary material distribution of the multi-machine-position carving roller positive beating refers to that carving rollers with different patterns are arranged on a plurality of control devices, and various dry granular glazes are distributed with patterns on the surface of a blank body through the carving rollers.

Preferably, the grain composition of the billet is: 30 meshes: less than or equal to 16 percent, 30-60 meshes: more than or equal to 70 percent, 60-80 meshes: less than or equal to 11 percent, 80 meshes below: less than or equal to 6 percent.

Preferably, in the step (3), a roller is adopted for pre-pressing forming, and the roller is a plane.

Preferably, in the step (5), a mold is used for compression molding, and the mold is a mold with a concave-convex effect or a plane mold.

Preferably, a drying step is further included between the step (5) and the step (6), and the green brick is dried to have the moisture content of less than or equal to 0.5 wt%.

Preferably, between step (5) and step (6), further comprising: applying protective glaze on the green brick, or uniformly scattering fine frit dry particles on the decorative pattern, wherein the particle size of the fine frit dry particles is preferably as follows: 0.5 to 1.5 mm. Thereby, the natural flow effect of the surface can be enhanced.

Preferably, the firing temperature is 1180-1220 ℃, and the firing period is 60-70 minutes.

The application also provides the flaky dry grain glaze cloth stone-like brick prepared by any one of the preparation methods.

The flaky dry grain glaze cloth stone-like brick can be a matte or highlight product and has the characteristics of vivid natural stone-like pattern, rich layers, natural texture, strong stereoscopic impression, strong granular sensation and the like. The surface of the ceramic tile presents three-in-one three-dimensional stone surface phase of bright light, soft light and natural surface creatively, the blending effect with the greatest regret property is brought for design and space application, and one stone has three surfaces and the surface is colored.

Drawings

FIG. 1 is a process flow diagram of one example of the present invention;

FIG. 2 shows a schematic view of a colorful flake-like dry-particle glaze production apparatus;

FIG. 3 shows a schematic diagram of an exemplary film dispenser configuration;

FIG. 4 shows an exemplary diagram of an engraved film;

FIG. 5 shows a schematic view of an exemplary embossing roll distribution device;

FIG. 6 shows a photograph of a shiny side of a stone-like tile of a sheeted dry-grain glazed cloth made in accordance with an example of the present invention;

FIG. 7 shows a photograph of a sheet-like dry-grain glaze (left) and a photograph of a natural face of a stone-like tile of a sheet-like dry-grain glaze cloth (right) made according to an example of the present invention;

FIG. 8 shows a large-scale tiling effect (matte) of a stone-like tile of sheeted dry-grain glazed cloth made according to an example of the present invention;

fig. 9 shows a large-size patchwork effect (matte) of a stone-like tile of a sheet-like dry-grain enamel cloth made according to another example of the present invention.

Detailed Description

The present invention is further described below in conjunction with the following embodiments and the accompanying drawings, it being understood that the drawings and the following embodiments are illustrative of the invention only and are not limiting. In the present invention, the content percentages are mass percentages unless otherwise specified.

In one embodiment of the invention, dry grain cloth and ink-jet printing are combined, and on the basis of carrying out detailed research and analysis on the surface texture of the natural stone, a plurality of cloth film patterns and ink-jet patterns with unique effects of imitating the texture of the natural stone are designed through high-precision scanning and aesthetic processing. During production, colorful flaky dry particle glaze (or flaky colorful special-shaped dry particle glaze or flaky special-shaped dry particle glaze) is prepared firstly, then the colorful flaky dry particle glaze is distributed on a blank in different patterns in a layered mode, and optionally, the colorful flaky dry particle glaze and powder dry particle glaze are mixed and then distributed on the blank in different patterns in a layered mode, namely, the colorful flaky dry particle glaze can be distributed on the blank independently or together with the powder dry particle glaze, and the requirements of pattern design are met. The powder dry grain glaze refers to round powder dry grain glaze, and can be colorful, namely colorful. The term "colorful" means that the colorful dry grain glaze has at least one color, and specifically, the colorful dry grain glaze can be a dry grain glaze of one color, can also be a mixture of multiple dry grain glazes of different colors, and can also be a dry grain glaze itself having multiple colors. Then adopting a mould with concave-convex effect or a plane mould to press green bricks; high-definition patterns of different stone textures are restored to the surface of the brick according to cloth patterns by a digital ink-jet printing technology, and finally, the stone-like product with vivid patterns, rich layers, natural textures, strong stereoscopic impression and granular sensation is obtained by high-temperature firing. In addition, after the ink-jet printing, protective glaze can be sprayed or fine fritted block dry particles can be uniformly scattered on the decorative pattern to strengthen the natural smooth effect of the surface.

Figure 1 shows a process flow diagram of one example of the invention. Hereinafter, the process flow will be specifically described with reference to fig. 1.

Pattern design

On the basis of carrying out detailed research and analysis on the surface texture of the natural stone, a plurality of dry grain glaze cloth patterns and ink-jet patterns imitating the texture effect of the natural stone are designed through high-precision scanning and aesthetic processing, and the dry grain glaze cloth patterns are matched and coordinated with the ink-jet patterns.

Specifically, the pattern is designed into two parts: firstly, the design of cloth patterns requires natural texture and stone effect; secondly, the design of the ink-jet pattern and the creative idea of color matching are derived from natural stone, and the artistic processing of removing impurities and retaining reality is carried out.

The two parts are designed in a mutual correlation mode, have complementary artistry and are formed through meticulous matching, and the natural fusion of the effects of the cloth pattern and the ink-jet pattern is ensured to be similar to the texture of natural stone.

Colorful flaky dry particle glaze

Hereinafter, a method for preparing a colorful flake-like dry-particle glaze will be described with reference to fig. 1 and 2.

Fig. 2 shows a schematic diagram of a colorful flaky dry particle glaze preparation device. As shown in fig. 2, slurry 1, slurry 2, and slurry 3 of different colors are loaded in slurry hoppers a, b, and c, respectively. Here, mixing of three different color slurries is exemplified, but it is to be understood that the present invention is not limited thereto as long as two or more color slurries are mixed. The specific gravity of each slurry can be 1.60-1.80. The slurry having a specific color may be obtained by mixing a colorant in the glaze slurry. The glaze may have a chemical composition of: SiO 2₂：55～65％、Al₂O₃：18～22％、Fe₂O₃：0.3～0.7％、TiO₂：0.1～0.35％、CaO：0.3～4.0％、MgO：0.5～1.5％、K₂O：2.0～3.5％、Na₂O: 2.5-6.0%, loss on ignition: 4.5 to 5.5 percent. As shown in fig. 1, the preparation of the glaze slurry may include dry glaze batching, ball milling, sieving to remove iron, and aging of the slurry.

The slurry hoppers a, b, c are communicated with the premix tank 4 through slurry pipes, and thus transport the slurry 1, the slurry 2, and the slurry 3 to the premix tank 4. The premix tank 4 is swingable (e.g., in a direction orthogonal to a conveyor belt described below) to mix the slurries 1, 2, 3 into a multicolor slurry (color-mixed multicolor slurry). Preferably, a plurality of slurry pipes 5 can be branched from the feed opening of each slurry hopper a, b, c. The plurality of slurry pipes 5 are distributed in a staggered manner, that is, the plurality of slurry pipes 5 are uniformly distributed on the premixing tank 4 along with the interfaces of the premixing tank 4, so that the slurry A, the slurry B and the slurry C can be uniformly conveyed into the premixing tank 4 to be better mixed.

The premix tank 4 opens downward. A tray 6 is provided below the premix tank 4. The distance between the open trays 6 of the premix tank 4 may be 3-5 cm. The multicolor slurry may be poured onto the tray 6 through the lower opening of the premix tank 4, and the multicolor slurry 8 is placed on the tray 6. The control of the thickness of the multicolored paste can be achieved by controlling the speed of the conveyor belt 7 as described below. The thickness of the multicolor slurry 8 can be 1-2 mm.

The tray 6 may be placed on the conveyor belt 7. The tray 6 with the multicolored slurry 8 can be transported on a conveyor belt 7 to a drying kiln for drying, resulting in a layer of multicolored slurry. The drying temperature can be 80-100 ℃, and the drying time can be 30-40 minutes. The water content of the colorful slurry layer obtained after drying can be lower than 1%. And crushing the colorful slurry layer obtained after drying. In one example, the fragmentation pattern is: pouring the colorful slurry layer into a vibrating screen, wherein the mesh number of the screen is 2-8 meshes. Then sieving to obtain the flake-shaped special-shaped dry grain glaze. When sieving, the sieve can be selected to be 4 meshes below and 10 meshes above. The thickness of the obtained flaky special-shaped dry granular glaze can be 0.8-1.5 mm, and the radial dimension can be 2-4.5 mm. A physical representation of an exemplary flake-like shaped dry-grain glaze is shown in the left diagram of fig. 7.

Powder dry particle glaze

In the invention, inorganic dry granular glaze can be adopted, which has the advantages of environmental protection and no toxicity. The chemical composition of the powder dry grain glaze can be consistent with the components of the common ceramic glaze. In one example, the chemical composition of the dry particle glaze is: SiO 2₂：55～65％、Al₂O₃：18～22％、Fe₂O₃：0.3～0.7％、TiO₂：0.1～0.35％、CaO：0.3～4.0％、MgO：0.5～1.5％、K₂O：2.0～3.5％、Na₂O: 2.5-6.0%, loss on ignition: 4.5 to 5.5 percent. The chemical composition of the colorful flaky dry particle glaze can be consistent with that of the powder dry particle glaze.

The powder dry glaze can have various colors. For example, the pigment can be added into white base glaze slurry according to the design requirement of the pattern, and the mixture is sprayed by a spray tower according to the particle composition and the water content requirement to obtain the product. Various high and low temperature frits may be added to the dry glaze to adjust the expansion coefficient of the dry glaze to match the expansion coefficient of the green body. In addition, the dry grain glaze can also have the effects of flashing and the like by adding a metal flashing sheet and the like. In one example, the colorful flaky dry particle glaze and the dry particle glaze with the effects of multiple colors, flashing and the like can be mixed according to different proportions, and the surface decoration effect of the brick is richer by matching the colorful flaky dry particle glaze and the dry particle glaze with the effects of multiple colors, flashing and the like.

The grain composition of the powder dry grain glaze can be as follows:

more than 30 meshes: 0

30-60 meshes: 30 to 37.5 percent

60-80 meshes: 42.5 to 50 percent

80-100 meshes: 12.5 to 17.5 percent

Under 100 meshes: less than or equal to 5 percent;

the dry granular glaze has larger particles, generates less dust in the process of distributing and producing, and is easy to collect.

Blank material

On the basis of matching with various physical and chemical properties of dry particles, in order to control the deformation degree of the brick, the content of alumina can be properly increased on the basis of a general blank formula, so that the high-temperature deformation resistance of a blank is enhanced, the expansion coefficient of the blank is reduced, the difference of the expansion coefficients of the blank and a glaze is reduced, the adaptability of the blank glaze is improved, and the control of the shape of the brick fired by a kiln is facilitated. In one embodiment of the present invention, the formulation of the blank is: by weight, SiO₂：60～67％、Al₂O₃：19～23％、Fe₂O₃：0.5～1.0％、TiO₂：0.15～0.30％、CaO：0.4～0.7％、MgO：0.3～0.8％、K₂O：2.5～3.5％、Na₂O: 2.7-3.5%, loss on ignition: 4.5 to 5.5 percent. The blank of the formula has excellent slurry performance, green body drying rate and drying strength, and has excellent physical and chemical properties after being fired. In the invention, the expansion coefficients of the blank and the glaze can be matched by adjusting the formula of the blank and/or the glaze, for example, the difference of the expansion coefficients is less than 1 x 10^-5and/K. Therefore, the defects of deformation, cracking of the special-shaped dry grain glaze and the like after the brick body is fired can be effectively overcome. In one example, the formulation chemistry of the green body is shown in table 1, and the expansion coefficient of the green body and glaze (e.g., including colorful flake dry glaze and powder dry glaze) is shown in table 2:

TABLE 1 Green body chemistry (wt%)

TABLE 2 comparison of expansion coefficients of green bodies and glazes

The method for producing the preform is not limited, and for example, a conventional method for producing a preform can be used. In one example, as shown in FIG. 1, the feedstock is first collected to conform to the formulated chemistry of the blank. Then, crushing the raw materials, preparing materials by a forklift, carrying out wet ball milling, sieving to remove iron, carrying out spray milling, and aging to obtain blank powder. The process parameters in the milling process can be as follows:

mud proportion: 1.69 to 1.71

Ball milling fineness: 1 to 1.2% (250 mesh screen)

Particle grading: 30 meshes: less than or equal to 16 percent

30-60 meshes: not less than 70 percent

60-80 meshes: less than or equal to 11 percent

80 meshes below: less than or equal to 6 percent

Moisture content of powder: 7.2 to 7.8 percent.

Cloth material

And (3) distributing the blank and the dry glaze, namely distributing the dry glaze on the blank according to different patterns by using a film. The dry glaze comprises colorful flaky dry glaze, and also can comprise powdery dry glaze and/or dry glaze with different colors and different shapes (such as at least one of granular shape, package shape and strip shape). In the invention, the dry grain cloth (fabric) can be carried out by adopting a multi-screen printing plate (multi-film). For example, 1 to 4 sheets of film can be used. The amount of each film stock (varying according to the pattern) can be: and (3) network connection film: 480-500 g, pattern film: 100-300 g. In one example, a TECNO ITALIA dispensing device is used to mix dry glaze (e.g., colorful flaky dry glaze, or granular, flaky, wrapped, and/or noodle-shaped dry glaze) in different proportions, and then a multi-film secondary dispensing system is used to achieve a multi-layer dispensing effect. Specifically, dry glaze (such as colorful flaky dry glaze or powder and special-shaped dry glaze with multiple colors) is distributed in a press mold cavity in different proportions and patterns in a layering manner by using a perforated film (or engraved film). Fig. 3 shows a schematic view of an exemplary film dispenser configuration. As shown in fig. 3, the film distributor comprises a dry grain glaze hopper 11, and an engraved film 12 located below the dry grain glaze hopper 11. The engraved film 12 can be wound at both ends around two film drive shafts 13, respectively. Under the engraved film 12 is placed a green brick 14 to be distributed. The dry grain glaze is discharged from a discharge port of a dry grain glaze hopper 11 onto the engraved film 12. The relative position of the engraved film 12 on the green brick 14 is changed by the rotation of the film transmission shaft 3, and dry grain glaze is coated on the green brick 14. Figure 4 shows an example engraved film. As shown in fig. 4, the machine position films are a machine position film 1, a machine position film 2, a machine position film 3 and a machine position film 4, wherein four groups of films jointly form two stone texture patterns, one row on the left corresponds to one group of stone texture patterns, one row on the right corresponds to one group of stone texture patterns, the machine position films correspond to different dry grains in the hopper, the patterns are different, the green bricks respectively and sequentially pass through the carving films, and the dry grains are sequentially distributed on the green bricks according to the carving patterns by rotating the films. In the invention, the dry grain glaze cloth stone-like brick can be produced by combining a multi-film dry grain cloth technology and a digital ink-jet printing technology on the basis of a common ceramic brick production process, so that a pattern with a natural stone surface decoration effect is perfectly reproduced on the surface of the ceramic brick.

The dry particle material distribution can also be carried out by adopting a mode of positively beating a multi-machine-position pattern carving roller to carry out secondary material distribution. Figure 5 shows a schematic view of an exemplary embossing roll distribution device. As shown in fig. 5, the device for distributing the engraved roll comprises a plurality of hoppers 111, 112, 113: and embossing

cylinders

114, 115, 116, respectively, located below each hopper. Below the embossing cylinders, the pre-pressed green bricks 117 are moved by means of a large driving belt 118 along the direction of arrangement of the embossing cylinders. And (3) feeding the colorful flaky dry grain glaze or dry grains with different colors or types into a hopper on the carving roller through a material pipe, and when the prepressed green bricks pass through the roller, distributing the dry grains in the roller on the green bricks according to the carved patterns through the carved holes. And then pressing and molding by a press, drying the molded green brick by a drying kiln, performing ink-jet printing and applying a covering glaze, and then performing kiln firing.

Initial forming

After the cloth is finished, the cloth is dry-pressed and molded as shown in fig. 1. In one embodiment, the green brick with certain strength is pre-pressed for the first time, then is subjected to ink-jet printing, and is subjected to compression molding by adopting a mold. In one example, pre-press forming is performed using a roll. The roller is a plane. The pressing pressure can be 300-360 bar, and the pressing period can be 3.5-4.5 times/min. In one example, the molding process is: a press machine type: PH 3000; molding pressure: 360 bar; and (3) pressing period: 3.8 times/min. Compared with the production of common glazed tiles, the invention reduces the wet glaze making process by adopting one-step molding of the blank glaze, does not additionally increase the emission of pollutants in the production and meets the requirement of environmental protection.

Ink jet printing

And (4) carrying out jet printing on the design pattern on the green brick by an ink jet machine erected on the distributor. As for the design of the pattern by ink jet printing, as shown in fig. 1, the material of the natural stone is selected, and high-precision scanning, pattern design, and color separation design are performed. The ink-jet printing pattern is matched with the dry particle cloth pattern to restore the high-definition patterns of different stone textures to the brick surface. Common colors of ink include pink, red brown, orange, light yellow, cyan, black, etc. The specific color can be selected according to the desired pattern to be formed.

Then, the mold is used for compression molding. In one example, a mold with a concave-convex effect or a plane mold is used for pressing a green brick. In order to achieve the surface concave-convex effect of the imitated natural stone, a mould with the surface effect of the imitated natural stone can be adopted. Specifically, the surface of the natural stone is scanned with high precision to obtain the pattern of the natural stone, and the pattern is distributed to the carving of each detail texture to obtain the surface effect of the imitated natural stone through artistic processing. That is, a mold with a vivid concave-convex effect is designed and manufactured by combining dry particle cloth (such as multi-machine engraved-roller dry particle cloth and multi-film cloth) and ink-jet patterns. During molding, the molding pressure can be 300-360 bar, and the pressing period can be 3.5-4.5 times/min.

The shaped green brick is dried as shown in fig. 1. The drying temperature may be 120 to 200 ℃, for example, 140 ℃, and the drying time may be 60 to 90 minutes, for example, 60 minutes. Preferably, the moisture content of the dried green body is less than or equal to 0.5 percent.

Optionally, after ink-jet printing, a protective glaze (e.g., a smolyticam, vitreric import glaze) or a full-polish clear glaze may be further applied. The high-definition patterns with different stone textures are restored to the surface of the brick by fusing a digital ink-jet printing technology and cloth patterns, and the matte or high-gloss product is formed by spraying protective glaze or fully polishing transparent glaze and then sintering at high temperature once. In one example, the formulation of the protective glaze may be: 12% of calcined kaolin, 5% of alumina, 18% of calcined talcum powder, 40% of potassium feldspar powder, 17% of calcite powder, 8% of kaolin, 0.2% of methyl, 0.35% of trimerization and 40% of water. The preparation of the protective glaze may include: collecting raw materials, preparing glaze materials, ball milling, sieving to remove iron, and aging for later use. According to the requirement, one of the glaze spraying and the glaze pouring can be selected to apply the protective glaze (or covering glaze). After the cover glaze is applied, on one hand, the antifouling effect can be achieved, and on the other hand, the ink-jet pattern can be protected from being worn off. In one example, the glazing process is as follows:

specific gravity of the cover glaze: 1.3-1.35 glaze spraying weight: 30-35 g/disc; or

Pouring glaze proportion: 1.78-1.86 weight of glaze pouring: 52. + -.2 g/disc.

Optionally, after ink-jet printing, the fine frit dry particles may be uniformly spread on the decorative pattern using a dry particle spreader to enhance the natural flow effect of the surface. The particle size of the fine frit dry particles may be 0.5 to 1.5 mm.

Then, as shown in fig. 1, the green body is subjected to primary firing. The firing temperature can be 1180-1220 ℃, and the firing period can be 60-70 minutes. After firing, the edge can be ground and packaged in grades. In one example, the firing process includes: and (3) firing in a kiln: a roller kiln; the highest firing temperature: 1220 ℃; and (3) firing period: and 65 min.

The obtained product has a unique stone-like texture style, and the dry particle cloth is highly matched with the ink-jet printing and die effects, so that the characteristic that the pattern of the product changes randomly is fully embodied. The stone-like brick has flaky colorful dry particle glaze decoration, can comprise three types of polished surfaces, matte surfaces and mold surfaces, and meets the requirements of consumers. FIG. 6 shows a photograph of a shiny side of a stone-like tile of a sheeted dry-grain glazed cloth made in accordance with an example of the present invention; the right hand picture in fig. 7 shows a photograph of a natural surface of a stone-like tile of a sheeted dry-grain glazed cloth made in accordance with an example of the present invention; FIG. 8 shows a large-scale tiling effect (matte) of a stone-like tile of sheeted dry-grain glazed cloth made according to an example of the present invention; fig. 9 shows a large-size patchwork effect (matte) of a stone-like tile of a sheet-like dry-grain enamel cloth made according to another example of the present invention. The invention can make the surface of the ceramic tile show three-in-one three-dimensional stone surface phase of bright light, soft light and natural surface. The stone-like brick with the flaky dry-particle glaze cloth has vivid patterns, rich layers, natural textures, strong stereoscopic impression and strong granular sensation.

The flaky dry particle cloth natural stone imitation brick series product combines colorful flaky dry particle glaze cloth with an ink-jet printing technology, so that the product has the characteristics of vivid stone imitation effect, rich layers, natural textures, strong stereoscopic impression and granular sensation and the like, and the product quality is greatly improved. The product has rich colors and sizes, wide application range, can be paved on the ground and also can be used for walls, can completely replace natural marble, and can be used for home decoration and commercial space. And can perform linear, curvilinear cutting and various complex processes.

The quality of the flaky dry-particle glaze cloth stone-like brick obtained by the invention meets the requirement of GB/T23266-2009 standard appendix G, the radioactivity index meets the requirement of A-type decoration materials in GB6566-2001 standard, and the application range is not limited. The main technical indexes are shown in the following table:

item

Water absorption rate

Modulus of rupture

Resistance to cracking of glaze

Stain resistance

Internal irradiation

External irradiation

Unit of

％

MPa

------

Results

0.05

38

Conform to

Grade 5

0.6

1.0

The fracture strength was 2338N, and the steel sheet was free from cracks or peeling in the test of vibration resistance, and had a wear resistance of 1500 rpm (class 3). The product has excellent anti-skid performance and excellent mechanical properties, and is a preferred material for high-grade decoration.

Claims

1. A preparation method of a colorful flaky dry particle glaze cloth stone-like brick is characterized by comprising the following steps:

(1) mixing glaze slips with different colors into colorful glaze slip, spraying the colorful glaze slip into a tray, drying to obtain a colorful mud slip layer, crushing the colorful mud slip layer, and sieving to obtain colorful flaky dry granular glaze, wherein the thickness of the obtained colorful flaky dry granular glaze is 0.8-1.5 mm, and the radial dimension of the obtained colorful flaky dry granular glaze is 2-4.5 mm;

(2) mixing the colorful flaky dry grain glaze and the colorful round powdery dry grain glaze, and then, layering the mixture according to the existing pattern on a pre-pressed green body, wherein the colorful flaky dry grain glaze and the colorful round powdery dry grain glaze have the same chemical composition and are SiO₂：55～65%、Al₂O₃：18～22%、Fe₂O₃：0.3～0.7%、TiO₂：0.1～0.35%、CaO：0.3～4.0%、MgO：0.5～1.5%、K₂O：2.0～3.5%、Na₂O: 2.5-6.0%, loss on ignition: 4.5-5.5%; the sum of the percentages of the components is 100 percent; the grain composition of the colorful round powdery dry grain glaze is as follows: 30-60 meshes: 30-37.5 wt%, 60-80 mesh: 42.5-50 wt%, 80-100 mesh: 12.5-17.5 wt%, 100 mesh: less than or equal to 5wt percent; the formula of the blank is as follows: by weight, SiO₂：60～67%、Al₂O₃：19～23%、Fe₂O₃：0.5～1.0%、TiO₂：0.15～0.30%、CaO：0.4～0.7%、MgO：0.3～0.8%、K₂O：2.5～3.5%、Na₂O: 2.7-3.5%, loss on ignition: 4.5-5.5%; the sum of the weight percentages of the components is 100 percent; the expansion coefficient difference between the blank and the glaze is less than 1 x 10 by adjusting the formula of the blank and/or the glaze^-5/K；

(3) After distributing, pressing a green brick;

(4) spraying and printing a design pattern on the green brick by using an ink-jet machine, and matching and coordinating the dry grain glaze cloth pattern in the step (2) with the ink-jet pattern to form a natural stone effect;

(5) and sintering the obtained green bricks.

2. The method according to claim 1, wherein the glaze slip has a specific gravity of 1.60 to 1.80; pouring the colorful glaze slurry into the tray with the thickness of 1-2 mm.

3. The preparation method according to claim 1, wherein the drying temperature is 80-100 ℃, the drying time is 30-40 minutes, and the water content of the colorful slurry layer obtained after drying is lower than 1%.

4. The method according to claim 1, wherein particles of 4 meshes and 10 meshes are taken as colorful flaky dry particle glaze during sieving.

5. The preparation method according to claim 1, wherein in the step (2), the material is distributed by using a multi-machine-position carving roller direct beating secondary material distribution method.

6. The method according to claim 1, further comprising, between step (4) and step (5): applying protective glaze on the green brick, or uniformly scattering dry particles of fine frits on the decorative pattern.

7. The method of claim 6, wherein the fine frit dry particles have a particle size of: 0.5 to 1.5 mm.

8. A multicolor flaky dry-grain glazed cloth stone-like tile produced by the production method of any one of claims 1 to 7.