CN110903080B - 特殊坯体大颗粒结合数码布料喷墨渗透抛光砖及其制备方法 - Google Patents

特殊坯体大颗粒结合数码布料喷墨渗透抛光砖及其制备方法 Download PDF

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CN110903080B
CN110903080B CN201911174146.7A CN201911174146A CN110903080B CN 110903080 B CN110903080 B CN 110903080B CN 201911174146 A CN201911174146 A CN 201911174146A CN 110903080 B CN110903080 B CN 110903080B
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刘一军
邓来福
杨元东
王贤超
程科木
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Monalisa Group Co Ltd
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Abstract

本发明公开特殊坯体大颗粒结合数码布料喷墨渗透抛光砖及其制备方法。所述喷墨渗透抛光砖的制备方法,包括以下步骤:(1)将面料、坯体大颗粒分别送入数码布料设备下料斗中,其中,所述坯体大颗粒包括白色坯体大颗粒、透明坯体大颗粒以及在透明坯体大颗粒配方基础上加入着色氧化物得到的半透明坯体大颗粒,所述坯体大颗粒中不包含助红剂和助黄剂;(2)采用数码布料设备将上述面料、坯体大颗粒按照设计效果布于底料上,成型得到坯体;(3)在所得坯体上打印喷墨图案;(4)烧成,抛光。

Description

特殊坯体大颗粒结合数码布料喷墨渗透抛光砖及其制备方法
技术领域
本发明涉及特殊坯体大颗粒结合喷墨渗透抛光砖工艺及其制备方法,属于陶瓷砖生产制造技术领域。
背景技术
随着陶瓷行业的高速发展以及人们对于空间美学的要求越来越高,从早期的抛光砖到抛釉砖,再到后来的喷墨渗花产品等等,陶瓷砖的产品类别已然十分丰富。而喷墨渗花产品由于兼具抛光砖的硬度耐磨和抛釉砖的花色,而受到广大消费者的青睐,但是常规渗花产品对比石材观赏和应用方面还是有一定的局限。
发明内容
针对上述问题,本发明的目的在于提供一种高度还原石材的喷墨渗透陶瓷砖及其制备方法。
第一方面,本发明提供一种喷墨渗透抛光砖的制备方法,其特征在于,包括以下步骤:
(1)将面料、坯体大颗粒分别送入数码布料设备下料斗中,其中,所述坯体大颗粒包括白色坯体大颗粒、透明坯体大颗粒以及在透明坯体大颗粒配方基础上加入着色氧化物得到的半透明坯体大颗粒,所述坯体大颗粒中不包含助红剂和助黄剂;
(2)采用数码布料设备将上述面料、坯体大颗粒按照设计效果布于底料上,成型得到坯体;
(3)在所得坯体上打印喷墨图案;
(4)烧成,抛光。
根据本发明,图案通过渗透墨水垂直渗透在坯体里面,由于坯体大颗粒中不包含助红剂和助黄剂,所以黄色和棕色打印在大颗粒上面也不会呈现颜色。这样经由抛光处理后,就可以看到白色和透明类似石材的颗粒在坯体里面,图案的立体感和层次非常强,可以达到更加逼真的石材效果。
较佳地,所述渗透面料的化学成分包括:SiO2:65~69%、Al2O3:18~21%、Fe2O3:0.16~0.46%、TiO2:0.3~0.6%、CaO:0.3~0.6%、MgO:0.2~0.5%、K2O:4.5~6%、Na2O:2.5~3.5%、ZrO2:0.5~2%、烧失:3.0~4.0%。
较佳地,所述白色坯体大颗粒的化学成分包括:SiO2:68~73%、Al2O3:15~18%、Fe2O3:0.06~0.16%、TiO2:0.1~0.2%、CaO:0.3~0.6%、MgO:1.4~2.5%、K2O:2.5~3.5%、Na2O:1.5~2.5%、烧失:4.0~5.0%。
较佳地,所述透明坯体大颗粒的化学成分包括:SiO2:60~65%、Al2O3:20~23%、Fe2O3:0.16~0.46%、TiO2:0.01~0.2%、CaO:2.5~3.5%、MgO:0.2~0.5%、K2O:3.5~4.5%、Na2O:2.0~3.0%、ZnO2:1.0~2.0%、烧失:3.5~4.5%。
较佳地,坯体大颗粒的粒径为6~12目。
较佳地,所述面料层总的布料量为1000~1200g/m2
较佳地,在步骤(3)和步骤(4)之间不用再施任何釉。
第二方面,本发明提供一种由上述任一制备方法制备的喷墨渗透抛光砖。
有益效果:本发明通过数码布料技术控制不同大颗粒布料的位置纹理,结合干法喷墨渗透工艺,使工艺和设计完美匹配,达到了高度还原石材的目的。而且,坯体大颗粒中不加入助红剂和助黄剂,烧成后渗透墨水在坯体大颗粒上不呈现颜色,经过抛光后,没有颜色的白色和透明以及着色半透明大颗粒可以使得产品得到更加逼真的石材效果,起到画龙点睛的作用。
附图说明
图1是本发明一实施方式的陶瓷砖的制备流程。
图2是实施例1得到的陶瓷砖的砖面效果图。
图3是实施例2得到的陶瓷砖的砖面效果图。
图4是实施例3得到的陶瓷砖的砖面效果图。
具体实施方式
以下通过下述实施方式进一步说明本发明,应理解,下述实施方式仅用于说明本发明,而非限制本发明。以下各百分含量如无特别说明均指质量百分含量。
图1示出本发明一实施方式的特殊坯体大颗粒结合喷墨渗透抛光砖(简称喷墨渗透抛光砖或陶瓷砖)的制备流程。
如图1所示,首先,将按要求制备好的面料、坯体大颗粒分别送入数码布料设备下料斗中。
面料(或称渗透面料)没有特别限定,可以是喷墨渗透抛光砖中常用的面料。渗透面料的粒径可与正常生产粉料粒径范围一致。一些实施方式中,渗透面料的化学成分包括:SiO2:65~69%、Al2O3:18~21%、Fe2O3:0.16~0.46%、TiO2:0.3~0.6%、CaO:0.3~0.6%、MgO:0.2~0.5%、K2O:4.5~6%、Na2O:2.5~3.5%、ZrO2:0.5~2%、烧失:3.0~4.0%。采用这样的渗透面料可以帮助渗透墨水棕色和黄色发色,拓展色域,使设计的选择和调整有较大的空间。
一些实施方式中,渗透面料的原料配方为水磨石粉28~33%、水磨钾长石粉30~35%、龙岩球土7~11%、钾砂12~15%、水洗球土5~8%、韶关球土3~6%、叶腊石2~5%、硅酸锆0.5~2%。
渗透面料中含有助红剂和助黄剂。助红剂是指可以促进渗透棕色墨水发色的物质,主要是气相二氧化硅。助黄剂是指可以促进渗透黄色墨水发色的物质,主要是二氧化钛等。
坯体大颗粒的粒径比渗透面料的粒径大,这样可以突出表现坯体大颗粒的效果。
坯体大颗粒的形状可为球形、各种异形等。
坯体大颗粒的粒径为6~12目,该粒径范围时可以在数码布料设备的喷头中很好的控制下料量,不会出现堵塞的现象,同时坯体大颗粒结合设计的效果搭配也较好。坯体大颗粒中不包含助红剂和助黄剂。
另外,坯体大颗粒可包括各种颜色的颗粒,例如可包括白色坯体大颗粒和透明坯体大颗粒以及在透明坯体大颗粒配方基础上加入着色氧化物得到的半透明坯体大颗粒。坯体大颗粒的颜色与渗透面料不同。
其中,白色坯体大颗粒的白度优选为62度以上。另外,白色坯体大颗粒的白度优选比渗透面料白度高5~10度,这样可以与面料拉开层次,可以更好地呈现产品的细节和层次。坯体大颗粒因为其中不含有助红剂和助黄剂,打印图案以后粒子上面不会呈现颜色,尤其是在仿天然石材中,点缀效果非常好。其中透明粒子温润如玉,白色粒子洁白高雅。半透明坯体大颗粒可以呈现类似有色宝石镶嵌在天然石材中的感觉,丰富了产品的细节,提升了产品的档次。
一些实施方式中,白色坯体大颗粒的化学成分包括:SiO2:68~73%、Al2O3:15~18%、Fe2O3:0.06~0.16%、TiO2:0.1~0.2%、CaO:0.3~0.6%、MgO:1.5~2.5%、K2O:2.5~3.5%、Na2O:1.5~2.5%、烧失:4.0~5.0%。采用这样的白色坯体大颗粒白度较好,大颗粒与面料之间的结合较好,其中MgO和K2O起到助熔和拓宽烧成范围的作用,减少大颗粒鼓包或者与面料结合开裂的现象。
一些实施方式中,白色坯体大颗粒的原料配方为钾长石25~30%、钠长石13~18%、球土8~12%、煅烧高岭土12~16%、石英15~20%、烧滑石粉3~6%。这些基础原料铁含量低,白度高,因此可以实现白色坯体大颗粒的无锆增白,节约了成本,减少了瓷砖的放射性。
一些实施方式中,透明坯体大颗粒的化学成分包括:SiO2:60~65%、Al2O3:20~23%、Fe2O3:0.16~0.46%、TiO2:0.1~0.2%、CaO:2.5~3.5%、MgO:0.2~0.5%、K2O:3.5~4.5%、Na2O:2.0~3.0%、ZnO2:1.0~2.0%、烧失:3.5~4.5%。采用这样的透明坯体大颗粒可以丰富产品的细节,该成分中高铝低钙高钾,这样可以升高透明大颗粒的烧成温度,拓宽坯体大颗粒的烧成范围,可以有效避免抛光后的毛孔。
一些实施方式中,透明坯体大颗粒的原料配方为球土13~18%、高强水洗泥13~18%、高白钾砂8~12%、透明高钙熔块18~23%、钾长石25~35%、钠长石8~12%。其中透明熔块为高钙熔块,这样抛光后的粒子透明度高、温润如玉,且闭气孔少,可以实现抛光后毛孔少,解决粒子抛光后防污性能的问题。高钙熔块可通过如下方法制备:提前将所需原料按比例混合均匀,通过1500℃高温熔炉熔融后猝水可得所需熔块。高钙熔块的原料配比为高岭土6~10%、方解石20~27%、烧滑石1~3%、钾长石28~35%、氧化锌7~10%、石英30~38%。
半透明坯体大颗粒可以通过在透明坯体大颗粒配方基础上加入着色氧化物得到。着色氧化物例如可选自氧化钴、氧化锰、三氧化二铁中的至少一种。
将底料与面料及坯体大颗粒通过数码布料、成型(例如压机干压成型),得到坯体。通过数码布料,可以按照设计需求,定位布大颗粒,达到更加逼真的仿石材效果。
底料没有特别限定,可以采用陶瓷砖领域常用的底料。
坯体可以进行干燥。一些实施方式中,干燥时长为1~1.5h,得到的干燥坯水分为0.3~0.5%。
然后,在坯体上打印喷墨图案。使用的墨水为渗透墨水。图案通过渗透墨水垂直渗透在坯体里面,由于坯体大颗粒中不包含助红剂和助黄剂,所以黄色和棕色打印在大颗粒上面也不会呈现颜色。这样经由抛光处理后,就可以看到白色和透明类似石材的颗粒在坯体里面,图案的立体感和层次非常强,可以达到更加逼真的石材效果。
干燥,例如通过电干燥或者热风干燥箱干燥。干燥温度可为100~150℃,干燥后水分可控制在0.5%以内。
然后,将所得的砖坯进行烧成。最高烧成温度范围可为1190~1220℃,烧成周期可为60~70分钟。烧成后可进行抛光。
本公开的喷墨渗透抛光砖,可根据设计,调整特殊坯体大颗粒的比例和大小,经由数码布料,再进行干压成型,喷墨打印机打印图案,干燥烧成抛光,工艺简单易操作,更高程度的还原石材,非常灵活方便。
下面进一步例举实施例以详细说明本发明。同样应理解,以下实施例只用于对本发明进行进一步说明,不能理解为对本发明保护范围的限制,本领域的技术人员根据本发明的上述内容作出的一些非本质的改进和调整均属于本发明的保护范围。下述示例具体的工艺参数等也仅是合适范围中的一个示例,即本领域技术人员可以通过本文的说明做合适的范围内选择,而并非要限定于下文示例的具体数值。
实施例1
喷墨渗透抛光砖的制备方法,包括以下步骤:
(1)将渗透面料、特殊坯体大颗粒分别装入数码布料设备料斗中。其中,面料化学组成为:SiO2:66.74%、Al2O3:18.39%、Fe2O3:0.30%、TiO2:0.34%、CaO:0.50%、MgO:0.23%、K2O:4.86%、Na2O:3.09%、ZrO2:1.64%、烧失:3.57%。渗透面料的粒径与正常生产粉料一致。特殊坯体大颗粒由白色坯体大颗粒和透明坯体大颗粒以及在透明大颗粒基础上加入着色氧化物而得到的着色半透明大颗粒组成。白色坯体大颗粒的白度为65,原料配方为:钾长石30%、钠长石15%、球土12%、煅烧高岭土12%、石英25%、烧滑石粉6%,化学组成为:SiO2:70.78%、Al2O3:16.02%、Fe2O3:0.11%、TiO2:0.11%、CaO:0.47%、MgO:2.19%、K2O:2.71%、Na2O:1.91%、烧失:4.63%。白色坯体大颗粒的颗粒大小为6~12目。透明坯体大颗粒的原料配方为:球土15%、高强水洗泥15%、高白钾砂10%、透明高钙熔块20%、钾长石30%、钠长石10%。,其中,透明熔块通过如下方法制得:高钙熔块可通过如下方法制备:提前将所需原料按比例混合均匀,通过1500℃高温熔炉熔融后猝水可得所需熔块。高钙熔块的原料配比为高岭土8%、方解石25%、烧滑石2%、钾长石30%、氧化锌9%、石英26%。透明坯体大颗粒的化学组成为:SiO2:61.70%、Al2O3:22.00%、Fe2O3:0.31%、TiO2:0.01%、CaO:2.73%、MgO:0.25%、K2O:4.31%、Na2O:2.42%、ZnO2:1.52%、烧失:3.64%。透明坯体大颗粒的颗粒大小为6~12目。半透明大颗粒是在透明大颗粒基础上加入氧化钴、氧化锰、三氧化二铁而得。
(2)采用数码布料车(购自赛普飞特公司,型号为SWB599)进行数码布料,压机干压成型;数码布料各种面料层总的布料量为1100g/m2
(3)干燥,干燥时长1h,干燥坯水分0.3%。
(4)打印喷墨图案。
(5)烧成,最高烧成温度1190℃,烧成周期65分钟。
(6)抛光磨边分级。
(7)打包入库。
图2示出本实施例得到的陶瓷砖的砖面效果图,可以看出通过数码定位布料技术结合喷墨渗透打印做到真假颗粒错落有致,黑色部分是渗透墨水打印的假颗粒,旁边小的其他颜色为应用数码布料技术布出的效果,真假颗粒相互衬托,做出了更加逼真和美观的仿石材效果。使用该配方的白色大颗粒和透明大颗粒抛光后毛孔少,防污性能良好。
实施例2
喷墨渗透抛光砖的制备方法,包括以下步骤:
(1)将渗透面料、特殊坯体大颗粒分别装入数码布料设备料斗中。其中,面料化学组成为:SiO2:66.74%、Al2O3:18.39%、Fe2O3:0.30%、TiO2:0.34%、CaO:0.50%、MgO:0.23%、K2O:4.86%、Na2O:3.09%、ZrO2:1.64%、烧失:3.57%。渗透面料的粒径与正常生产粉料一致。特殊坯体大颗粒由白色坯体大颗粒和透明坯体大颗粒以及在透明大颗粒基础上加入着色氧化物而得到的着色半透明大颗粒组成。白色坯体大颗粒的白度为68,原料配方为:钾长石30%、钠长石15%、球土14%、煅烧高岭土12%、石英25%、烧滑石粉4%,化学组成为:SiO2:70.54%、Al2O3:16.83%、Fe2O3:0.12%、TiO2:0.11%、CaO:0.43%、MgO:1.47%、K2O:2.76%、Na2O:1.91%、烧失:4.63%。白色坯体大颗粒的颗粒大小为6~12目。透明坯体大颗粒的原料配方为:球土10%、高强水洗泥10%、高白钾砂20%、透明高钙熔块20%、钾长石30%、钠长石10%。,其中,透明熔块通过如下方法制得:高钙熔块可通过如下方法制备:提前将所需原料按比例混合均匀,通过1500℃高温熔炉熔融后猝水可得所需熔块。高钙熔块的原料配比为高岭土8%、方解石25%、烧滑石2%、钾长石30%、氧化锌9%、石英26%。透明坯体大颗粒的化学组成为:SiO2:63.90%、Al2O3:20.10%、Fe2O3:0.26%、TiO2:0.01%、CaO:2.66%、MgO:0.22%、K2O:4.46%、Na2O:2.68%、ZnO2:1.55%、烧失:4.12%。透明坯体大颗粒的颗粒大小为6~12目。半透明大颗粒是在透明大颗粒基础上加入氧化钴、氧化锰、三氧化二铁而得。
(2)采用数码布料车进行数码布料,压机干压成型;数码布料各种面料层总的布料量为1100g/m2
(3)干燥,干燥时长1h,干燥坯水分0.3%。
(4)打印喷墨图案。
(5)烧成,最高烧成温度1190℃,烧成周期65分钟。
(6)抛光磨边分级。
(7)打包入库。
图3示出本实施例得到的陶瓷砖的砖面效果图,可以看出通过提高白色坯体大颗粒中的球土的含量,升高配方的烧结温度,在一定程度上可以增加白色大颗粒的白度,可以更加鲜明的突出粒子的高雅洁净,适当降低透明颗粒中的铝含量,可以增加透明颗粒的透感,能够更好的呈现出类似石材中晶体的感觉,再加上数码定位布料技术结合喷墨渗透打印做出了更加逼真和美观的仿石材效果。使用该配方的白色大颗粒和透明大颗粒抛光后毛孔少,防污性能良好。
实施例3
喷墨渗透抛光砖的制备方法,包括以下步骤:
(1)将渗透面料、特殊坯体大颗粒分别装入数码布料设备料斗中。其中,面料化学组成为:SiO2:66.74%、Al2O3:18.39%、Fe2O3:0.30%、TiO2:0.34%、CaO:0.50%、MgO:0.23%、K2O:4.86%、Na2O:3.09%、ZrO2:1.64%、烧失:3.57%。渗透面料的粒径与正常生产粉料一致。特殊坯体大颗粒由白色坯体大颗粒和透明坯体大颗粒以及在透明大颗粒基础上加入着色氧化物而得到的着色半透明大颗粒组成。白色坯体大颗粒的白度为63,原料配方为:钾长石28%、钠长石17%、球土14%、煅烧高岭土12%、石英25%、烧滑石粉4%,化学组成为:SiO2:70.62%、Al2O3:16.42%、Fe2O3:0.12%、TiO2:0.11%、CaO:0.45%、MgO:1.87%、K2O:2.53%、Na2O:2.03%、烧失:4.63%。白色坯体大颗粒的颗粒大小为6~12目。透明坯体大颗粒的原料配方为:球土15%、高强水洗泥10%、高白钾砂15%、透明高钙熔块20%、钾长石30%、钠长石10%,其中,透明熔块通过如下方法制得:高钙熔块可通过如下方法制备:提前将所需原料按比例混合均匀,通过1500℃高温熔炉熔融后猝水可得所需熔块。高钙熔块的原料配比为高岭土8%、方解石25%、烧滑石2%、钾长石30%、氧化锌9%、石英26%。透明坯体大颗粒的化学组成为:SiO2:62.82%、Al2O3:20.91%、Fe2O3:0.25%、TiO2:0.01%、CaO:2.63%、MgO:0.25%、K2O:4.03%、Na2O:2.84%、ZnO2:1.56%、烧失:4.29%。透明坯体大颗粒的颗粒大小为6~12目。半透明大颗粒是在透明大颗粒基础上加入氧化钴、氧化锰、三氧化二铁而得。
(2)采用数码布料车进行数码布料,压机干压成型;数码布料各种面料层总的布料量为1100g/m2
(3)干燥,干燥时长1h,干燥坯水分0.3%。
(4)打印喷墨图案。
(5)烧成,最高烧成温度1190℃,烧成周期65分钟。
(6)抛光磨边分级。
(7)打包入库。
图4示出本实施例得到的陶瓷砖的砖面效果图,可以看出增加钠长石的含量,会降低白色大颗粒的白度;而适当增加透明大颗粒中的铝含量,可以使透明大颗粒白色半透明状,类似天然石材晶粒的感觉,通过数码定位布料技术结合喷墨渗透做出了更加逼真和美观的仿石材效果。使用该配方的白色大颗粒和透明大颗粒抛光后毛孔少,防污性能良好。

Claims (4)

1.一种喷墨渗透抛光砖的制备方法,其特征在于,包括以下步骤:
(1)将含有助黄剂和助红剂的渗透面料、不包含助红剂和助黄剂的坯体大颗粒分别送入数码布料设备下料斗中;渗透面料的原料配方为:水磨石粉 28~33%、水磨钾长石粉 30~35%、龙岩球土 7~11%、钾砂 12~15%、水洗球土 5~8%、韶关球土 3~6%、叶腊石 2~5%、硅酸锆 0.5~2%;所述坯体大颗粒包括白色坯体大颗粒、透明坯体大颗粒以及在透明坯体大颗粒配方的基础上加入着色氧化物得到的半透明坯体大颗粒;
白色坯体大颗粒的原料配方为钾长石 25~30%、钠长石 13~18%、球土 8~12%、煅烧高岭土 12~16%、石英 15~20%、烧滑石粉 3~6%;所述白色坯体大颗粒的化学成分包括:SiO2:68~73%、Al2O3:15~18%、Fe2O3:0.06~0.16%、TiO2:0.1~0.2%、CaO:0.3~0.6%、MgO:1.4~2.5%、K2O:2.5~3.5%、Na2O:1.5~2.5%、烧失:4.0~5.0%;
所述白色坯体大颗粒的白度比渗透面料的白度高5-10度,为62度以上;
透明坯体大颗粒的原料配方为球土 13~18%、高强水洗泥 13~18%、高白钾砂 8~12%、透明高钙熔块 18~23%、钾长石 25~35%、钠长石 8~12%;所述透明坯体大颗粒的化学成分包括:SiO2:60~65%、Al2O3:20~23%、Fe2O3:0.16~0.46%、TiO2:0.01~0.2%、CaO:2.5~3.5%、MgO:0.2~0.5%、K2O:3.5~4.5%、Na2O:2.0~3.0%、ZnO:1.0~2.0%、烧失:3.5~4.5%;
所述坯体大颗粒的粒径大于渗透面料的粒径,为6~12目;
(2)采用数码布料设备将上述渗透面料、坯体大颗粒按照设计效果布于底料上,成型得到坯体;
(3)在所得坯体上使用渗透墨水打印喷墨图案;
(4)烧成,抛光,图案通过渗透墨水垂直渗透在坯体里面,且烧成后渗透墨水在坯体大颗粒上不呈现颜色,获得图案立体感和层次强的所述喷墨渗透抛光砖。
2.根据权利要求1所述的制备方法,其特征在于,所述渗透面料的化学成分包括:SiO2:65~69%、Al2O3:18~21%、Fe2O3:0.16~0.46%、TiO2:0.3~0.6%、CaO:0.3~0.6%、MgO:0.2~0.5%、K2O:4.5~6%、Na2O:2.5~3.5%、ZrO2:0.5~2%、烧失:3.0~4.0%。
3.根据权利要求1所述的制备方法,其特征在于,在步骤(3)和步骤(4)之间不用再施任何釉。
4.一种由权利要求1至3中任一项所述的制备方法制备的喷墨渗透抛光砖。
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