CN107902900B

CN107902900B - Wrapped dry particle glaze, wrapped dry particle glaze cloth stone-like brick and preparation method thereof

Info

Publication number: CN107902900B
Application number: CN201711132182.8A
Authority: CN
Inventors: 刘一军; 赵勇; 杨元东; 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: 2021-03-19
Anticipated expiration: 2037-11-15
Also published as: CN107902900A

Abstract

The invention relates to a coated dry particle glaze, a coated dry particle glaze cloth stone-like brick and a preparation method thereof. The preparation method of the wrapped dry granular glaze comprises the following steps: and dripping the glaze slurry into a rotating disc filled with glaze powder, coating the glaze powder into coated particles by rotating the glaze droplets through the rotation of the disc, and drying to obtain the coated dry particle glaze. The invention can obtain the wrapped dry grain glaze through a simple process, and the wrapped dry grain glaze 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

Wrapped dry particle glaze, wrapped dry particle glaze cloth stone-like brick and preparation method thereof

Technical Field

The invention relates to a coated dry particle glaze, a coated stone-like brick with the coated dry particle glaze and a preparation method of the coated stone-like brick, and belongs 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 a wrapped 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.

One aspect of the application provides a preparation method of a coated dry-particle glaze, which is characterized by comprising the following steps:

and dripping the glaze slurry into a rotating disc filled with glaze powder, coating the glaze powder into coated particles by rotating the glaze droplets through the rotation of the disc, and drying to obtain the coated dry particle glaze.

According to the invention, the wrapped dry granular 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 granular sensation can be obtained.

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

Preferably, the water content of the glaze powder in the tray is 6-10%.

Preferably, the grain composition of the glaze powder in the tray is 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.

The glaze powder can be a single color or can be multi-colored (i.e., have at least two colors). The glaze slip may be a single color.

The application also provides a preparation method of the wrapped dry grain glaze cloth stone-like brick, which comprises the following steps:

(1) preparing a wrapped dry grain glaze according to any one of the preparation methods;

(2) distributing the wrapped dry granular glaze on the blank according to the existing patterns 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 wrapping dry glaze and the powder dry glaze are distributed in layers in advance and are molded into a green brick, and then the dry glaze 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 stereoscopic impression and granular sensation can be obtained.

Preferably, the wrapping dry grain glaze and the powder dry grain glaze are distributed on the blank according to the existing patterns 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: 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. 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 wrapped dry grain glaze cloth has rough patterns and fine ink-jet patterns, the two 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 coated dry particle glaze cloth stone-like brick prepared by any one of the preparation methods.

The wrapped dry grain glaze cloth stone-like brick can be a matte or highlight product and has the characteristics of vivid and 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 wrapped-shaped dry-particle glaze production plant;

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 wrapped dry-grain glazed cloth stone-like tile made in accordance with an example of the present invention;

FIG. 7 shows a photograph of a wrapped dry-grain glaze cloth stone-like tile made in accordance with an example of the present invention (left) and a photograph of a natural surface of the wrapped dry-grain glaze cloth stone-like tile (right);

FIG. 8 shows a large-scale tiling effect (matte) of a wrapped-shaped dry-grain glazed cloth stone-like tile made in accordance with an example of the present invention;

fig. 9 shows a large-size patchwork effect (matte) of a wrapped-type dry-grain glaze cloth stone-like tile manufactured 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, the wrapped dry glaze is firstly prepared, then the wrapped dry glaze is layered and distributed on the blank according to different patterns, and optionally, the wrapped dry glaze and the powder dry glaze are mixed and then layered and distributed on the blank according to different patterns, namely, the wrapped dry glaze can be distributed on the blank independently or together with the powder dry glaze, depending on the design requirements of the patterns. The powder dry grain glaze refers to round powdery dry grain glaze and can be 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.

Wrapped dry particle glaze

Hereinafter, a method for preparing the coated dry glaze particles will be described with reference to fig. 1 and 2. Fig. 2 shows a schematic view of a package-shaped dry-particle glaze preparation device. As shown in fig. 2, the apparatus comprises a vertically arranged rotating shaft 1. The rotating shaft 1 can rotate around the axis thereof, and the rotating speed can be 30-60 revolutions per minute. A disk 3 is fixed to the rotating shaft 1. The disc 3 is rotatable with rotation of the rotating shaft 1. The shape of the disk 3 is not particularly limited, and is, for example, circular, that is, a circular disk. Preferably, the rotation shaft 1 is inserted through the center of the disc 3. The carrying surface of the disk 3 may have a certain inclination angle, preferably 10 to 30 degrees, with the axis of the rotary shaft 1. The benefits of having a tilt angle for the tray 3 are mainly two-fold: 1. the glaze powder can have better fluidity when the inclined disc rotates, and is more beneficial to the glaze powder to be fully wrapped on the outer layer of the glaze slip; 2. after the package type dry particle glaze is successfully prepared, the machine stops rotating, and particles can be deposited below the package type dry particle glaze, so that the package type dry particle glaze is convenient to collect.

Glaze powder is contained in the tray 3. The glaze powder can be single color or multi-color. The glaze powder with a specific color can be formed by mixing glaze and toner. The glaze material comprises the following chemical components: 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 water content of the glaze powder can be 6-10%. If the moisture content is too low, dust is easy to be raised when the machine rotates; if the water content is too high, the glaze powder is likely to be agglomerated when the machine rotates. The grain composition of the glaze powder can be as follows: 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.

A slurry hopper 4 is provided above the tray 3, and a slurry (glaze slurry) 5 is filled in the slurry hopper 4. The glaze slip may be a single color. The slurry having a specific color may be obtained by mixing a colorant in the glaze slurry. Specifically, as shown in fig. 1, the preparation steps of the glaze slip may include dry glaze proportioning, ball milling, sieving to remove iron, aging the slip, and color matching. 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.

The distance from the discharge port of the pulp hopper 4 to the carrying surface of the disc 3 can be 50-100 cm. The aperture of the discharge hole of the slurry hopper 4 can be 2-5 mm. The slurry 5 may drip from the discharge port of the slurry hopper 4 into the tray 3. By the rotating rotation of the plate 3, the glaze droplets wrap the glaze powder in the upper plate 3 into wrapping-shaped particles, such as wrapping spherical particles. The wrapped dry granular glaze is formed by wrapping a layer of glaze material on the surface of glaze powder, and forming a circular granule on the surface of a pressed and formed brick, and the wrapped dry granular glaze is similar to a circular crystal granule in natural stone, and has an effect closer to the natural stone compared with a non-wrapped granular dry granular glaze. The particle size of the obtained coated particles can be 4-8 mm.

And drying the coated particles to obtain the coated dry granular glaze. The drying temperature can be 80-100 ℃, and the drying time can be 30-40 minutes. The water content of the wrapped dry granular glaze can be lower than 3 percent. Due to the special manufacturing process of the wrapped dry grain glaze, a circular ring-shaped particle is formed on the surface of the pressed and formed brick, and the wrapped dry grain glaze is similar to a circular crystal particle in natural stone, and has an effect closer to the natural stone compared with a non-wrapped granular dry grain glaze. A physical representation of an exemplary encapsulated dry glaze is shown in the left image 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 compositions of the coated dry granular glaze and the powder dry granular glaze can be consistent.

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 wrapping dry particle glaze and the dry particle glaze with multi-color and/or flash effects and the like can be mixed according to different proportions, and the surface decoration effect of the brick is richer by matching the wrapping dry particle glaze and the dry particle glaze.

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. Thereby, canSo as to effectively solve the defects of deformation, cracking of the special-shaped dry grain glaze and the like after the brick body is fired. 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 encapsulated 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 coated dry glaze particles, and also can comprise powder dry glaze particles and/or other dry glaze particles with different colors and different shapes (such as at least one of granular glaze particles, flaky glaze particles and strip glaze particles). 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 cloth device is adopted to mix dry particle glaze materials (such as wrapped dry particle glaze materials, or granular, flaky, wrapped and/or noodle-shaped dry particle glaze materials with different colors) according to different proportions, and a multi-film secondary cloth system is adopted to realize a multi-layer cloth effect. Specifically, dry glaze (such as wrapped dry glaze or powder and special dry glaze with multiple colors) is distributed in a press mold cavity in different proportions and patterns in a layering mode by using a perforated film (or carved 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) conveying the wrapped dry glaze or dry grains with different colors or types into a hopper on the carving roller through a material pipe, and when the pre-pressed 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 wrapped 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 wrapped dry-grain glazed cloth stone-like tile made in accordance with an example of the present invention; the right hand image in fig. 7 shows a photograph of a natural surface of a wrapped dry-grain glazed cloth stone-like tile made in accordance with one example of the present invention; FIG. 8 shows a large-scale tiling effect (matte) of a wrapped-shaped dry-grain glazed cloth stone-like tile made in accordance with an example of the present invention; fig. 9 shows a large-size patchwork effect (matte) of a wrapped-type dry-grain glaze cloth stone-like tile manufactured 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 wrapped dry grain glaze cloth stone-like brick has vivid patterns, rich layers, natural textures, strong stereoscopic impression and granular impression.

The wrapped dry grain glaze cloth and the ink-jet printing technology are combined in the wrapped dry grain cloth imitated natural stone brick series products, so that the products have the characteristics of vivid stone imitated 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 wrapped dry grain glaze cloth stone-like brick 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 coated dry particle glaze cloth stone-like brick is characterized by comprising the following steps:

(1) preparing a wrapped dry-particle glaze, comprising:

dripping the glaze slurry into a rotating disc filled with colored glaze powder, coating the glaze powder by rotating the glaze droplets through the rotation of the disc to form coated particles, and drying to obtain coated dry granular glaze; the wrapped dry granular glaze is formed by wrapping a layer of glaze material on the surface of glaze powder; the grain composition of the glaze powder in the tray is as follows: 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;

(2) the method comprises the following steps of (1) distributing wrapping dry glaze and powder dry glaze on a blank body formed by pre-pressing a blank according to existing patterns in a layered mode, wherein the powder dry glaze is powder prepared from glazes with the same or different temperature formulas and colors, and the particle grading of the powder dry 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 chemical composition of the powder dry grain glaze is as follows: 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: 4.5-5.5%, wherein the sum of the weight percentages of the components is 100%; the chemical composition 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%, wherein the sum of the weight percentages of the components is 100%; wherein the difference of expansion coefficients of 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) Pressing the mixture into green bricks after material distribution;

(4) selecting natural stone materials, carrying out high-precision scanning, pattern design and color separation design to obtain design patterns, then carrying out jet printing on the design patterns on the green bricks by using an ink jet machine, and mutually matching and coordinating the existing patterns in the step (2) and the design patterns in the step (4) to form the effect of the natural stone materials;

(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.

3. The method of claim 1, wherein the tray is at an oblique angle to the horizontal.

4. The method according to claim 3, wherein the inclination angle is 10 to 30 degrees.

5. The method according to claim 1, wherein the water content of the glaze powder in the tray is 6 to 10%.

6. The production method according to any one of claims 1 to 5, 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 wrapped dry-grain glazed cloth stone-like tile produced by the production method according to any one of claims 1 to 7.