CN109293399B - Dry granular brick with stone grain embossed feeling and preparation method thereof - Google Patents
Dry granular brick with stone grain embossed feeling and preparation method thereof Download PDFInfo
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- C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
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- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
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Abstract
The invention relates to a dry granular brick with stone pattern embossed feeling and a preparation method thereof, wherein the preparation method comprises the following steps: applying base coat on the green brick, and performing ink-jet printing on a stone-like pattern; applying glue on the stone texture of the ink-jet pattern and then distributing dry particles on the brick surface; and applying a covering glaze on the brick surface, and then sintering.
Description
Technical Field
The invention relates to a dry granular brick with stone grain embossed feeling and a preparation method thereof, belonging to the technical field of production and manufacturing of ceramic bricks.
Background
Natural stone is widely used in the field of decoration due to its durability and great sense of thickness, but as natural stone is a non-renewable resource, with development year by year, the storage amount of natural stone is reduced year by year and natural stone has a certain radioactivity, with people's higher and higher attention to radioactivity, more and more consumers are more inclined to adopt ceramic tiles to replace stone for house decoration. Under the stimulation of market demands, various ceramic production enterprises are developing stone-like ceramic tiles, and the types of the stone-like ceramic tiles are more and more, and the color and texture of the stone-like ceramic tiles can be comparable to that of stone. The defect in the beauty is that the crystal feeling and the texture with the crystal feeling of the natural stone are difficult to imitate.
Disclosure of Invention
In view of the above problems, an object of the present invention is to provide a method for producing a dry granular brick having a stone-like embossed feeling, and a dry granular brick having a stone-like embossed feeling produced by the production method.
On one hand, the invention provides a preparation method of a dry particle brick with a stone pattern embossed feeling, which comprises the following steps:
applying base coat on the green brick, and performing ink-jet printing on a stone-like pattern;
applying glue on the stone texture of the ink-jet pattern and then distributing dry particles on the brick surface; and
and applying a covering glaze on the brick surface, and then sintering.
The invention provides the natural-like dry grain brick with the stone grain embossed feeling by combining ink-jet printing and cloth dry grains.
Preferably, the chemical composition of the dry pellets is: by mass, SiO2：55～60％、Al2O3：5～10％、CaO：6～10％、MgO：0.3～3％、K2O：5～8.0％、Na2O: 1.5-3.0%, ZnO: 6-12%, BaO: 0.5-2%, PbO: 0.5-1%, loss on ignition: 0.2 to 0.5 percent.
Preferably, the particle size distribution of the dry particles is 0.1-2% of the particle size distribution on a 60-mesh sieve, 30-45% of the particle size distribution on a 60-80-mesh sieve, 25-30% of the particle size distribution on a 80-100-mesh sieve, 20-25% of the particle size distribution on a 100-140-mesh sieve, and the particle size distribution on the 140-mesh sieve is as follows: 3-8%.
Preferably, after the dried pieces are distributed, the non-bonded dried pieces are removed, and the non-bonded dried pieces are preferably removed by an exhaust fan.
Preferably, the chemical composition of the ground glaze is as follows: by mass, SiO2：57～60％、Al2O3：23～25％、Fe2O3：0.3～0.4％、TiO2：0.1～0.2％、CaO：0.3～0.4％、MgO：0.1～0.3％、K2O：4～6％、Na2O：2～3.0％、ZrO2: 6-12%, loss on ignition: 3-5%.
Preferably, the specific gravity of the ground coat is 1.40-1.45, and the glazing weight is 40-550 g/m2。
Preferably, the chemical composition of the cover glaze is as follows: by mass, SiO2：50～55％、Al2O3：12～16％、CaO：9～12.8％、MgO：3～6％、K2O：0.5～3.0％、Na2O: 2-5.0%, ZnO: 4-6%, loss on ignition: 3-5%.
Preferably, the specific gravity of the cover glaze is 1.30-1.45, and the glazing amount is 200-400 g/m2。
Preferably, the maximum firing temperature is 1200-1220 ℃, and the firing period is 40-60 minutes.
In another aspect, the present invention provides a dry granular brick having a stone-grained embossed feeling, which is produced by any one of the above-mentioned methods.
The ceramic tile produced by the invention has vivid color of the imitated natural stone, natural and protruding texture, good concave-convex feeling and good anti-skid effect.
Drawings
FIG. 1 is a production flow diagram of one embodiment of the present invention.
FIG. 2 shows an inkjet pattern of an inkjet printer according to an embodiment of the present invention.
Fig. 3 shows a glue pattern of a glue pellet dryer in accordance with an embodiment of the present invention.
FIG. 4 is a face view of a finished brick in accordance with an embodiment 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 thereof. The following percentages are by mass unless otherwise specified.
FIG. 1 shows a production flow diagram of an embodiment of the present invention. As shown in fig. 1, first, a green body is prepared. The green body can be prepared from known ceramic raw materials by a conventional method, such as sequentially carrying out blank ball milling, powder spraying granulation, press dry pressing molding and drying in a drying kiln to obtain a dried blank. The water content of the dried blank can be controlled within 0.4 percent.
Then, a base coat is applied on the green body. The ground glaze can cover the blank body and facilitate color development.
In one embodiment, the base coat has a chemical composition of: by mass, SiO2：57～60％、Al2O3：23～25％、Fe2O3：0.3～0.4％、TiO2：0.1～0.2％、CaO：0.3～0.4％、MgO：0.1～0.3％、K2O：4～6％、Na2O：2～3.0％、ZrO2: 6-12%, loss on ignition: 3-5%. The base glaze with the chemical composition has high whiteness, wide firing temperature range and good color development of various ceramic inks.
The ground coat application method includes but is not limited to glaze spraying, glaze pouring and the like. The fineness of the ground glaze slip can be 325 meshes and less than 0.6 percent. The specific gravity of the ground glaze slip is 1.40-1.45, and the surface of the brick is fine and smooth after glaze spraying under the specific gravity. The flow rate of the ground glaze slip can be 20-25 seconds, wherein the flow rate refers to that the flow rate cup is filled with the object to be measured, a small hole below the flow rate cup is opened, and the time from the beginning to the end of the flow of the object to be measured is recorded as the flow rate of the object to be measured. The weight of the ground coat applied per unit area can be 400-550 g/m2Preferably 480 to 500g/m2. The glaze applying amount can ensure that the glaze is smooth and the moisture brought in can be discharged in time. The thickness of the ground coat layer can be 0.05-0.10 mm.
Then, the stone-like document was ink-jet printed. The ink can be printed by a digital ink-jet printer. The ceramic ink mainly has blue, brown, orange, lemon yellow, black, red, etc. The ink jet printed pattern is for example as shown in fig. 2.
And applying glue ink on the stone texture of the ink-jet pattern. The material of the glue ink is not particularly limited, and may be a glue known in the art. The application method can be digital printing and the like. In one embodiment, a digital glue pellet dryer is used to spray glue ink. Figure 3 illustrates an exemplary glue dryer glue pattern. The ink amount of the glue spraying water is different according to the gray level change of the design of the glue spraying water pattern, and the gray level range can be controlled to be 30-100%. The width range of the lines of the pattern can be 1mm at the minimum, and the maximum width can be changed according to the texture of the stone, for example, the width can be 100 mm. GlueThe amount of the water ink applied may be 25 to 50g/m2. The glue amount can be adopted to ensure that the amount of the bonded dry particles is moderate, and the digital printer can reach and stably spray-print.
After the glue ink is applied, dry particle frits (dry particles or dry particle glazes for short) are uniformly distributed on the surface of the brick. In one embodiment, the application of the glue ink and the cloth dry granulation can be performed by using a digital glue dry granulation machine.
In a preferred embodiment, the chemical composition of the dry pellets is: by mass, SiO2：55～60％、Al2O3：5～10％、CaO：6～10％、MgO：0.3～3％、K2O：5～8.0％、Na2O: 1.5-3.0%, ZnO: 6-12%, BaO: 0.5-2%, PbO: 0.5-1%, loss on ignition: 0.2 to 0.5 percent. Wherein, ZnO can reduce the high-temperature viscosity of the dry particles and is beneficial to the color development of the ceramic ink, and PbO can greatly reduce the softening temperature of the dry particles and is more beneficial to the melting of the dry particles.
In a more preferred embodiment, the frit dry-particle glaze has a chemical composition of: by mass, SiO2：55.5～60％、Al2O3：6.5～10％、CaO：9～10％、MgO：2.2～2.8％、K2O：5.5～6.5％、Na2O: 1.5-2.0%, ZnO: 10-12%, BaO: 1.5-2.0%, PbO: 0.5-0.7%, loss on ignition: 0.25 to 0.30 percent.
In a preferred embodiment, the grain composition of the dried grains is 0.1-2% of the grain size of 60 meshes, 30-45% of the grain size of 60-80 meshes, 25-30% of the grain size of 80-100 meshes, 20-28% of the grain size of 100-140 meshes, and 140 meshes below: 3-8%. The dry particles with the particle grading can form compact accumulation during material distribution, fine particles can fill gaps in the melting process, and the fired dry particle glaze layer has a good melting effect and no defects such as bubbles.
The dry granules can be applied in a quantity of 400-600 g/m2. When the cloth is applied, the effect of the dried brick grains on the brick surface is good, all the dried grains can be well bonded, and the cost is moderate. The dry granules can be applied to a thickness of 1.0 to 2.0 mm. When the cloth is applied to the brick, the floating sense is strong, and the influence on the brick shape is small.
In a preferred embodiment, after the dried pellets are distributed, the non-bonded, solid pellets are removed. The removed dry particles can be recycled. In one example, the unbonded dry pellets are removed with a suction fan. The resulting dried pellets can then be recovered and sieved for reuse.
And then, covering glaze is applied on the brick surface on which the dry grains are distributed, so that a protective layer can be added on the surface of the dry grain glaze layer, the adhesion of the dry grain glaze is improved, and the dry grains are prevented from being blown off by airflow in the kiln in the firing process of the kiln. The cover glaze may be a transparent glaze.
In a preferred embodiment, the chemical composition of the cover glaze is: by mass, SiO2：50～53％、Al2O3：12～16％、CaO：9～12.8％、MgO：3～6％、K2O：0.5～3.0％、Na2O: 2-5.0%, ZnO: 4-6%, loss on ignition: 3-5%. The cover glaze has good permeability, moderate glossiness and fine hand feeling after sintering.
In a more preferred embodiment, the chemical composition of the cover glaze is: by mass, SiO2：52.2～54.8％、Al2O3：13.2～16.5％、CaO：10.2～12.8％、MgO：3.1～4.2％、K2O：1.3～2.2％、Na2O: 3.2-3.6%, ZnO: 5.2-5.8%, loss on ignition: 3.5 to 4.8 percent.
The means for applying the cover glaze includes, but is not limited to, spraying glaze, pouring glaze, etc. The fineness of the cover glaze slip can be 0.6-0.8% (325 mesh screen). The specific gravity of the cover glaze slip can be 1.30-1.45, and the fired brick surface is fine and smooth after glaze spraying and atomizing effects are good under the specific gravity. The flow rate of the cover glaze slip can be 8-12 seconds. The weight of the cover glaze applied per unit area can be 200-400 g/m2Preferably 240 to 300g/m2. The glaze with the glazing amount can be uniformly distributed on the dry particles without influencing the performance of the dry particles. The thickness of the cover glaze layer can be 0.05-0.08 mm. The thickness of the brick has good hand feeling, and meanwhile, the brick can be well fused with dry particles, and the antifouling performance of the brick surface is more excellent.
And then firing is performed. The low-temperature quick firing can be adopted, for example, the firing period can be 40-60 minutes, and the maximum firing temperature can be 1200-1220 ℃.
Polishing, edging and grading can be carried out. The polishing thickness can be 0.05-0.08 mm.
Fig. 4 shows the product obtained in one embodiment of the invention, which shows that the product has vivid color like natural stone, natural and convex texture, good concave-convex feeling and good anti-skid effect. The ceramic tile has the glossiness of 5-20 degrees, the surface is soft, and the static friction coefficient can reach 0.6-0.85.
The present invention will be described in detail by way of examples. It is also to be understood that the following examples are illustrative of the present invention and are not to be construed as limiting the scope of the invention, and that certain insubstantial modifications and adaptations of the invention by those skilled in the art may be made in light of the above teachings. The specific process parameters and the like of the following examples are also only one example of suitable ranges, i.e., those skilled in the art can select the appropriate ranges through the description herein, and are not limited to the specific values exemplified below.
Example 1
And (5) performing dry pressing molding by a press.
Drying in a drying kiln, wherein the moisture content of the dried blank is less than 0.4%.
Spraying surface glaze (or ground glaze), specific gravity 1.42, glazing weight 480g/m2The overglaze comprises the following chemical components: SiO 22：58.3％、Al2O3：24.2％、Fe2O3：0.31％、TiO2：0.13％、CaO：0.34％、MgO：0.23％、K2O：4.86％、Na2O：2.5％、ZrO2: 8.5%, loss on ignition: 3.66 percent.
The stone-like document is printed by ink-jet printing with a digital ink-jet printer (available from Froude Co., Ltd.) using ceramic inks mainly of blue, brown, orange, lemon yellow, black, red, etc.
Digitally printing glue ink on the stone texture of the ink-jet pattern, and using a digital glue granulating machine (purchased from B)&T company) was uniformly laid a layer of dry-granulated clinker on the brick surface, the clinker amount was 600g/m2(ii) a The grain composition of the dry grain glaze is 0.18 percent of that of a 60-mesh sieve,40.6 percent of 60-80 mesh sieve, 26.9 percent of 80-100 mesh sieve, 27.1 percent of 100-140 mesh sieve and the following 140 mesh sieve: 5.22 percent. The dry granular glaze comprises SiO2：59.4％、Al2O3：6.8％、CaO：9.6％、MgO：2.5％、K2O：5.8％、Na2O: 1.7%, ZnO: 11.5%, BaO: 1.8%, PbO: 0.6%, loss on ignition: 0.3 percent.
And pumping the non-bonded dry granules by using an exhaust fan, recovering and sieving the non-bonded dry granules, and then recycling the non-bonded dry granules.
Spraying covering glaze with the specific gravity of 1.35 and the glazing amount of 250g/m2The chemical composition of the cover glaze is as follows: SiO 22：54.5％、Al2O3：14.6％、CaO：11.4％、MgO：4.0％、K2O：2.0％、Na2O: 3.4%, ZnO: 5.5%, loss on ignition: 4.6 percent.
The high-temperature-resistant ceramic material is quickly sintered by adopting a roller kiln, the maximum sintering temperature is 1200-1220 ℃, and the sintering period is 40-60 min.
And (5) edging, grading, packaging and warehousing.
Detecting the glossiness through a glossiness meter; and detecting the static friction coefficient by a friction coefficient detector. Through detection, the glossiness of the ceramic tile is 13 degrees, the toilet surface is soft, the static friction coefficient reaches over 0.75, and the ceramic tile has a good anti-skidding effect.
Example 2
Basically the same as example 1, except that the chemical composition of the dry granular glaze is as follows: SiO 22：57.1％、Al2O3：9.2％、CaO：9.3％、MgO：2.2％、K2O：6.0％、Na2O: 1.8%, ZnO: 12%, BaO: 1.6%, PbO: 0.5%, loss on ignition: 0.3 percent.
Through detection, the glossiness of the ceramic tile is 10.5 degrees, the toilet surface is soft, the static friction coefficient reaches 0.82, and the ceramic tile has a good anti-skidding effect.
Example 3
Basically the same as example 1, except that the grain composition of the dried glaze particles is 2% on a 60-mesh sieve, 40% on a 60-80-mesh sieve, 26% on a 80-100-mesh sieve, 27% on a 100-140-mesh sieve and the following 140-mesh sieve: 5 percent.
Through detection, the glossiness of the ceramic tile is 9.5 degrees, the toilet surface is soft, the static friction coefficient reaches 0.85, and the ceramic tile has a good anti-skidding effect.
Example 4
Basically the same as example 1, except that the dry glaze particles contain SiO2：56.2％、Al2O3：10％、CaO：9.0％、MgO：2.3％、K2O：6.5％、Na2O: 2.0%, ZnO: 11.5%, BaO: 2.0%, PbO: 0.5%, loss on ignition: 0.3 percent. By detection, the glossiness of the tile is 8.4 degrees, the toilet surface is soft, and the static friction coefficient reaches 0.82.
Example 5
Essentially the same as example 1, except that the grain composition of the dry glaze particles is: 2 percent of 60-mesh sieve, 40 percent of 60-80-mesh sieve, 30 percent of 80-100-mesh sieve, 25 percent of 100-140-mesh sieve and the following 140-mesh sieve: 3 percent. By detection, the glossiness of the tile is 9.5 degrees, the surface of the tile is soft, and the static friction coefficient reaches 0.86.
Comparative example 1
Basically the same as example 1, except that the dry glaze particles contain SiO2：58.7％、Al2O3：15％、CaO：9.5％、MgO：2.3％、K2O：6.5％、Na2O: 6.0%,: 11.5%, BaO: 2.0%, loss on ignition: 0.3 percent. The formula does not contain ZnO and PbO, and CaO and K in the formula are increased2O、Na2And O, the purpose of reducing the melting temperature of the dry particle glaze is achieved, and by contrast, the ceramic ink obtained by firing the formula becomes dark in color and contains more small bubbles. ZnO and PbO can promote the elimination of air bubbles in the glaze.
Claims (7)
1. A preparation method of a dry particle brick with a stone pattern embossed feeling is characterized by comprising the following steps:
applying base coat on the green brick, and performing ink-jet printing on a stone-like pattern;
applying glue on the stone texture of the ink-jet pattern and then distributing dry particles on the brick surface; the chemical composition of the dry granules is as follows: by mass, SiO2：55～60%、Al2O3：5～10%、CaO：6～10%、MgO：0.3～3%、K2O：5～8.0%、Na2O: 1.5-3.0%, ZnO: 6-12%, BaO: 0.5-2%, PbO: 0.5-1%, loss on ignition: 0.2-0.5%; the particle size composition of the dry particles is as follows: 0.1-2% of 60-mesh sieve, 30-45% of 60-80-mesh sieve, 25-30% of 80-100-mesh sieve, 20-25% of 100-140-mesh sieve and 140-mesh sieve below: 3-8%; the glazing amount of the dry particles is 400-600 g/m2(ii) a And
applying covering glaze on the surface of the brick; the chemical composition of the covering glaze is as follows: by mass, SiO2：50～53%、Al2O3：12～16%、CaO：9～12.8%、MgO：3～6%、K2O：0.5～3.0%、Na2O: 2-5.0%, ZnO: 4-6%, loss on ignition: 3-5%; the specific gravity of the cover glaze is 1.30-1.45, and the glazing amount is 200-400 g/m2；
Then, firing;
the glossiness of the dry particle brick with the stone grain embossed feeling is 5-20 degrees, and the static friction coefficient is 0.6-0.85.
2. The method of claim 1, wherein after the cloth dried pellets, the non-bonded solid dried pellets are removed.
3. The method according to claim 2, wherein the non-adhered dried pellets are removed by an exhaust fan.
4. The method according to claim 1, characterized in that the chemical composition of the under-glaze is: by mass, SiO2：57～60%、Al2O3：23～25%、Fe2O3：0.3～0.4%、TiO2：0.1～0.2%、CaO：0.3～0.4%、MgO：0.1～0.3%、K2O：4～6%、Na2O：2～3.0%、ZrO2: 6-12%, loss on ignition: 3-5%.
5. The method according to claim 1, wherein the ground coat has a specific gravity of 1.40 to 1.45 and a glaze application amount of 40 to 550g/m2。
6. The production method according to claim 1, wherein the maximum firing temperature is 1200 to 1220 ℃ and the firing period is 40 to 60 minutes.
7. A dry granulated brick having a stone-like embossed feeling produced by the production method according to any one of claims 1 to 6.
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