CN111004038A - Ultra-large specification thin porcelain plate with electric heating function and production method thereof - Google Patents

Ultra-large specification thin porcelain plate with electric heating function and production method thereof Download PDF

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CN111004038A
CN111004038A CN202010001813.8A CN202010001813A CN111004038A CN 111004038 A CN111004038 A CN 111004038A CN 202010001813 A CN202010001813 A CN 202010001813A CN 111004038 A CN111004038 A CN 111004038A
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ultra
porcelain plate
thin porcelain
blank
glaze
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CN111004038B (en
Inventor
赵明
夏昌奎
余爱民
余剑峰
张文民
樊叶利
蒋孝云
李德发
李志富
谢明锋
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Deqing Nabel Ceramic Co ltd
Jiujiang Nabel Ceramic Co ltd
Hangzhou Nabel Ceramic Co ltd
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Deqing Nabel Ceramic Co ltd
Jiujiang Nabel Ceramic Co ltd
Hangzhou Nabel Ceramic Co ltd
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    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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    • B32—LAYERED PRODUCTS
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    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00—Duplicating or marking methods; Sheet materials for use therein
    • B41M5/0041—Digital printing on surfaces other than ordinary paper
    • B41M5/0047—Digital printing on surfaces other than ordinary paper by ink-jet printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
    • B41M—PRINTING, DUPLICATING, MARKING, OR COPYING PROCESSES; COLOUR PRINTING
    • B41M5/00—Duplicating or marking methods; Sheet materials for use therein
    • B41M5/0041—Digital printing on surfaces other than ordinary paper
    • B41M5/007—Digital printing on surfaces other than ordinary paper on glass, ceramic, tiles, concrete, stones, etc.
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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
    • C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • 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
    • C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
    • C03C8/14—Glass frit mixtures having non-frit additions, e.g. opacifiers, colorants, mill-additions
    • C03C8/20—Glass frit mixtures having non-frit additions, e.g. opacifiers, colorants, mill-additions containing titanium compounds; containing zirconium compounds
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Abstract

The invention discloses an ultra-large specification thin porcelain plate with an electrothermal function and a production method thereof, wherein the production method comprises the following steps: A. preparing blank powder for the ultra-large specification thin porcelain plate according to a conventional method; B. preparing a ground glaze and a polishing glaze for the ultra-large specification thin porcelain plate according to a conventional method; C. distributing blank powder and performing die-free pressing forming; D. automatic green body cutting; E. drying the blank; F. baking; G. applying a base glaze for the ultra-large specification thin porcelain plate; H. drying; I. ink-jet printing; J. applying polishing glaze for ultra-large specification thin porcelain plates; K. drying for the third time; l, firing; m, edging; n, compound electric heat layer and insulating layer. The invention has the beneficial effects that the invention provides the ultra-large specification thin porcelain plate with the electric heating function and the production method thereof, solves the problems that the blank body of the thin porcelain plate is easy to damage after the traditional thin porcelain plate adopts the wet glaze pouring and other water-containing decoration processes, and the defects of 'water ripple', 'frame', 'glaze curtain pull wire' and the like appear after the glaze is applied on the surface of the blank body, expands the decoration means of the ultra-large specification thin porcelain plate, is not only suitable for the anhydrous decoration process, but also can well apply the water-containing decoration process, obviously enriches the decoration style of the ultra-large specification thin porcelain plate, improves the decoration effect, and endows the ultra-large specification thin porcelain plate with the electric heating function.

Description

Ultra-large specification thin porcelain plate with electric heating function and production method thereof
Technical Field
The invention relates to the technical field of building ceramics, in particular to an oversized thin porcelain plate with an electrothermal function and a production method thereof.
Background
The natural stone is influenced by long-term geological motion and climate change and is mixed with associated minerals with other colors, so that high-end, natural and rich decorative effects are formed, and the natural stone is favored by people as a high-grade decorative material. However, the radioactive minerals associated with some natural stones may cause radioactive damage to human health; the natural stone affected by geological action and weathering has more defects such as impurities, cracks and the like, is easy to generate pathological changes, and has poor service performance. In addition, the natural stone is used as an unrenewable resource, is expensive and is difficult to enter common families; the transitional mining and processing of natural stones not only causes the exhaustion of rare and rare stone resources, but also seriously damages the natural ecological environment.
Under the circumstances, products such as ceramic tiles and ceramic plates mainly based on stone imitation are continuously developed on the market. According to the definition of ceramic tiles of the national standard GB/T4100-. The general specification is 0.6m × 0.6m (upper surface area 0.36 m)2) 0.8 m.times.0.8 m (upper surface area 0.64 m)2) The maximum can reach 1.2m multiplied by 1.2m (the upper surface area is 1.44 m)2）。
According to the definition of the ceramic plate of the national standard GB/T23266-2009 ceramic plate, the ceramic plate is a plate-shaped ceramic product which is made of clay and other inorganic non-metallic materials through the production processes of forming, high-temperature firing and the like, the thickness of the ceramic plate is not more than 6mm, and the upper surface area of the ceramic plate is not less than 1.62m2。
Chinese patent CN105622055A provides a method for preparing large-size ultrathin building ceramic tile blanks, which comprises the steps of mixing a plurality of raw materials according to a certain mass percentage, preparing slurry by a wet method, pressing into strips by a semi-dry pressing forming method, and sintering for 2 hours at a certain temperature to obtain the ceramic blanks. The method is to obtain a ceramic blank by drying and sintering a large-size ultrathin building ceramic tile after the ceramic blank is molded without texture decoration on the ceramic blank. Chinese patent CN101634185 discloses a large-sized porcelain tile imitating jade quality and a preparation method thereof, wherein a base material is distributed by pattern fixed point distribution, a semitransparent ceramic material and toner are applied to form a surface layer, and then the product is obtained by the working procedures of pressing, forming, drying, firing and the like. It can be found that in the prior art, the cloth and semi-dry pressing are mostly adopted to form a sheet blank, and then the sheet blank is dried and fired to prepare a large-size sheet, while the wet-process glaze slurry is sprayed and applied after the formed blank is adopted, and the water-containing decoration process of re-decoration, drying and firing is not reported. Therefore, the decoration effect of the ultra-large thin porcelain plate is limited.
The anhydrous decoration process refers to a decoration process of powder/dry particle cloth decoration, full-digital non-aqueous ink jet decoration or combination thereof adopted by the ceramic blank. The water-containing decoration process is a decoration process which at least adopts one of glaze and glaze with the water content of not less than 20 percent, screen printing glaze, roller printing glaze and water-based ink for decoration in one or more working procedures of the decoration process, and can be combined with powder/dry particle cloth decoration and non-water-based ink decoration.
The invention provides a thin porcelain plate with an ultra-large specification and an electrothermal function and a production method thereof, the thin porcelain plate produced by the technical scheme of the invention has large specification and thin thickness, is not only suitable for an anhydrous decoration process, but also suitable for a hydrous decoration process, has three-dimensional lines on decorative pattern textures, has vivid texture and decoration effect of natural stone, has no defects and radioactive hazards of the natural stone, can replace the natural stone, and enters the families; the electric heating ceramic board can also reduce the exploitation and processing of rare and precious stone materials, reduce the influence and damage to the natural environment, and endow the ultra-large thin ceramic board with an electric heating function, can be used for ground paving or desktop application, and can also provide warmth for the indoor space in cold winter and preserve heat for food on the desktop.
Disclosure of Invention
The invention aims to solve the problems that the large-specification thin porcelain plate decoration means in the prior art is limited, the decoration effect is not rich enough, and the large-specification thin porcelain plate blank is easy to have the defects of breakage, 'water ripple', 'frame', 'glaze curtain pull wire' and the like after being subjected to a water-containing decoration process, particularly wet glazing decoration, and endow the thin porcelain plate with an electric heating function, and provides the ultra-large-specification thin porcelain plate with the electric heating function and the production method thereof. The super large thin ceramic plate with electrothermal function is a plate-shaped ceramic product made of clay and other inorganic non-metal materials through the production processes of forming, high-temperature firing and the like, and has the water absorption rate of not more than 0.5 percent, the thickness of not more than 6mm and the upper surface area of not less than 1.62m2。
The invention also aims to provide a super-large-specification thin porcelain plate product with an electrothermal function, which is produced by using the method.
In order to realize the invention purpose of producing a super-large specification thin porcelain plate with an electric heating function, the technical scheme of the invention is as follows: a production method of an ultra-large specification thin porcelain plate with an electric heating function comprises the following steps:
A. preparing blank powder for the ultra-large thin porcelain plate according to a conventional method for later use;
B. preparing a ground glaze for an oversized thin porcelain plate according to a conventional method, and preparing a polishing glaze for an oversized thin porcelain plate with an anti-slip function according to the conventional method, wherein the polishing glaze comprises the chemical composition of SiO in percentage by weight2：45%~50%、Al2O3：20%~28%、CaO：0~8%、MgO：0~3%、K2O：1%~5%、Na2O：1%~5%、ZnO：0~5%、BaO：10%~15%、ZrO2: 0-5% for standby;
C. distributing blank powder and performing die-free press molding: b, performing the blank powder for the ultra-large thin porcelain plate prepared in the step A according to the designed pattern textureDistributing, and forming by a die-free compression molding process to obtain a blank body of the ultra-large thin porcelain plate, wherein the bulk density of the formed blank body is more than or equal to 1.95g/cm3；
D. Automatic green body cutting: c, automatically cutting the blank of the ultra-large thin porcelain plate which is formed by die-free pressing in the step C to obtain the required specification and size of the blank;
E. drying the blank: d, drying the ultra-large specification thin porcelain plate blank subjected to automatic blank cutting in the step D according to a conventional method;
F. baking: e, baking the ultra-large thin porcelain plate blank dried in the step E, wherein the baking temperature is 500-800 ℃, the baking period is 5-15 min, and the volume weight of the baked ultra-large thin porcelain plate blank is more than or equal to 1.80g/cm3The modulus of rupture of the baked green body is more than or equal to 3.0 MPa;
G. applying a base glaze for the ultra-large specification thin porcelain plate: b, applying the ground glaze for the ultra-large thin porcelain plate prepared in the step B on the surface of the ultra-large thin porcelain plate blank baked in the step F by using an ultra-large spraying disc, wherein the diameter of the end face circle of the lower end of the ultra-large spraying disc is more than or equal to 2400 mm;
H. and (3) drying again: drying the blank body of the ultra-large specification thin porcelain plate after the ground coat for the ultra-large specification thin porcelain plate is applied in the step G again according to a conventional method;
I. ink-jet printing: spraying ceramic ink on the ultra-large thin porcelain plate blank dried again in the step H by using a digital ink-jet printer according to a designed pattern, and matching with the pattern texture of the blank, so that the surface after ink-jet printing and the blank have similar texture and texture, and the temperature of the blank before ink-jet printing is 40-70 ℃;
J. applying polishing glaze for ultra-large specification thin porcelain plates: b, applying the polishing glaze for the ultra-large thin porcelain plate with the slip limiting function, which is prepared in the step B, on the surface of the ultra-large thin porcelain plate blank subjected to ink jet printing in the step I by adopting the ultra-large shower tray in the step G;
K. and (3) drying for the third time: drying the blank body of the ultra-large thin porcelain plate which is applied in the step J and has the anti-slip function and is polished with glaze for the ultra-large thin porcelain plate for the third time according to a conventional method;
l, firing: placing the ultra-large specification thin porcelain plate blank dried for the third time in a roller kiln for sintering, wherein the sintering temperature is 1150-1250 ℃, and the sintering period is 60-150 min, so as to obtain an ultra-large specification thin porcelain plate semi-finished product;
m, edging: and D, utilizing conventional edging processing equipment to carry out edging treatment on the semi-finished product of the ultra-large specification thin porcelain plate prepared in the step L to prepare a finished product of the ultra-large specification thin porcelain plate with an electrothermal function, wherein the thickness of the finished product is less than or equal to 6mm, and the upper surface area of the finished product is more than or equal to 1.62m2；
And N, taking one or two of porous ceramics and ceramic microspheres as a heat insulation layer, compounding an electric heating layer on the surface of the heat insulation layer by using sealant, compounding a decorative layer on the surface of the electric heating layer, wherein the electric heating layer is a graphene film provided with an electrode and a temperature control system, and the decorative layer is a semi-finished product of the ultra-large thin porcelain plate prepared in the step M, and finally producing the ultra-large thin porcelain plate with an electric heating function.
In the above steps, the conventional control means in the prior art is adopted, unless otherwise specified.
In order to accomplish the second purpose of the invention, the ultra-large specification thin porcelain plate product with the electrothermal function is produced according to the steps.
As a further technical scheme, high-fire frits and/or corundum materials are introduced into the polishing glaze for the ultra-large thin porcelain plate with the anti-slip function in the step B, so that a mixed crystal phase of celsian and anorthite is generated in a polishing glaze layer of the ultra-large thin porcelain plate, and point-shaped hard protrusions are formed on the surface of the polishing glaze and are uniformly distributed, so that the good anti-slip function can be realized.
As a further technical scheme, the volume weight uniformity of each part of the ultra-large specification thin porcelain plate blank in the step C is good, and the volume weight difference between any two parts in the same ultra-large specification thin porcelain plate blank is less than or equal to 0.1g/cm3。
And C, the volume weight is calculated according to the national standard GB/T3810.3-2016 ceramic tile test method part 3: measurement of Water absorption, apparent porosity, apparent relative density and volume weight, volume weight is a quotient of the dry weight of the sample divided by the apparent volume (including pores). The performance of the invention is mainly used for measuring the densification degree of a finished product after the thin porcelain plate blank is molded/dried and sintered. The bulk weight of the blank after the ultra-large specification thin porcelain plate is subjected to die-free press forming has extremely important significance, and on one hand, the method represents the densification degree of the blank after the ultra-large specification thin porcelain plate is formed, so that the blank can meet the requirement of the green strength of the subsequent process, and simultaneously ensures the sufficiency of the reaction among the powder particles of the ultra-large specification thin porcelain plate blank in the firing process; on the other hand, the volume weight difference between any two parts in the same ultra-large thin porcelain plate blank is less than or equal to 0.1g/cm by adjusting the die-free compression molding process and the performance of the powder of the ultra-large thin porcelain plate blank3And the compactness of each part of the blank of the ultra-large specification thin porcelain plate is controlled to be uniform, so that the simultaneous shrinkage and densification of each part of the ultra-large specification thin porcelain plate can be realized in the drying and sintering processes, and the improvement of the flatness of the ultra-large specification thin porcelain plate after drying and sintering is facilitated.
The baking in the step F mainly has the following functions:
the method can solve the problems that the ultra-large specification thin porcelain plate blank is easy to damage and the like caused by adopting a water-containing decoration process, particularly wet glaze spraying decoration after the ultra-large specification thin porcelain plate blank is formed. The wet-process glaze pouring application form is generally suitable for ceramic tiles with small specifications (the general specification is less than 900mm multiplied by 900 mm) or ceramic tiles with large thickness (the general thickness is more than 6 mm), but can not be directly applied to large-specification and even ultra-large-specification thin ceramic plates because the weight of an ultra-large-specification thin ceramic plate blank is much larger than that of the ceramic tiles with the traditional specifications (even thicker ceramic tiles), although the ultra-large-specification thin ceramic plate blank has certain green strength after being dried, if the wet-process glaze pouring mode is adoptedMicroscopically, water molecules in glaze permeate into a crystal lattice frame of powder on the surface of a blank due to hydration, mineral molecules in the powder on the surface of the blank react with water molecules to generate solvated particles, the dissolving process of the powder is promoted, the cohesion between the powder on the surface of the blank is further reduced, macroscopically, the powder on the surface of the blank absorbs moisture and expands, the surface bonding strength of the blank is damaged, and the green strength of the upper half part of the blank is sharply reduced, and a narrow strip-shaped conveying line (convenient for slurry recovery) is adopted during glaze spraying instead of a wide belt-shaped conveying line, so that the blank of a thin porcelain plate with an ultra-large specification is easily deformed and even exceeds the maximum deformation amount which the blank can bear to cause damage, particularly when the specification of the thin porcelain plate with the ultra-large specification is 900mm multiplied by 1800mm (the upper surface area is 1.62 m)2) Increase to 1600mm multiplied by 5200mm (upper surface area 8.32 m)2) This effect is more pronounced. After the baking process of the step F is adopted, the ultra-large thin porcelain plate blank has certain strength, and the hydration effect can be greatly weakened, so that the blank damage is greatly reduced.
And step F, enabling organic matters in the ultra-large thin porcelain plate blank to be discharged, and being beneficial to improving the surface quality of the ultra-large thin porcelain plate prepared after firing, wherein the temperature of the baking process is 500-800 ℃, the temperature stage belongs to a preheating zone of a traditional kiln, various organic matters in the ultra-large thin porcelain plate blank begin to be discharged at the stage, if carbonate and sulfate exist, the organic matters begin to decompose and discharge gas, intermolecular crystal water is removed, the blank shrinks and weight loss rapidly increases, clay structure water begins to be discharged, and β -quartz in the blank is transformed to α -quartz crystal phase at the temperature of 573 ℃ or so, and volume expansion is accompanied.
And thirdly, the decoration means and the decoration effect are enriched. The prior art mostly adopts the anhydrous decoration process of drying and firing after cloth and semi-dry pressing are molded into an oversized thin porcelain plate blank, and adopts the water-containing decoration process of spraying wet-process glaze slurry after the blank is molded, and then decorating, drying and firing, and the main reason is that the spraying of the wet-process glaze slurry easily causes various problems along with the great reduction of the thickness and the great increase of the specification of the porcelain plate, such as the reduction of the strength of the blank and the difficulty in meeting the requirements of the subsequent production process. Therefore, the decoration means and decoration effect of the ultra-large specification thin porcelain plate are limited. After the baking process of the step F of the invention is adopted, the thin porcelain plate can have certain strength (the modulus of rupture is more than or equal to 3 MPa), and the method is not only suitable for the anhydrous decoration process, but also suitable for the hydrous decoration process, thereby enriching the decoration means and the decoration effect of the ultra-large thin porcelain plate.
And fourthly, compared with the traditional biscuit firing process, the baking process in the step F of the invention also has obvious advantages. Bisque firing refers to a process of heat treatment of a green body at a certain temperature to make the green body have a certain mechanical strength. The biscuit firing temperature is 900-1100 ℃, the biscuit firing period is 50-100 min, and the biscuit firing temperature is high, so that the blank of the ultra-large thin porcelain plate has certain strength (the modulus of rupture is more than or equal to 10 MPa), the powder particles of the blank in the blank are rapidly gathered, air holes are extruded, the blank structure is remarkably densified, the adsorption capacity of the blank of the ultra-large thin porcelain plate after biscuit firing on wet process glaze slip is weakened, and the implementation of large-amount wet process glaze slip and other water-containing decoration processes is not facilitated. Compared with the prior art, the temperature of the baking process is lower, the period is shorter, the baked ultra-large thin porcelain plate blank has a strong adsorption capacity to wet glaze slip besides a certain strength (the modulus of rupture is more than or equal to 3 MPa), and the method is suitable for wet glaze pouring and other water-containing decoration processes; on the other hand, compared with biscuit firing, the baking temperature is lower, the period is shorter, the energy consumption of the kiln is lower, the production flow is quicker and more efficient, and the production cost is obviously reduced.
The traditional wet-process glaze pouring manner is easy to have a 'water ripple' defect, especially for large-size products, and the defect is that after the specification of the product is increased, the matched glaze pouring equipment is increased in size along with the increased size to aggravate mechanical shock, and the glaze curtain area is increased along with the increased size to cause uneven glaze slurry distribution and the like to cause uneven glaze slurry distribution, so that the surface of the product after being polished has ripple-like fluctuation like water surface ripple, and the surface decoration effect is influenced. Secondly, the glaze slurry is applied on the ultra-large specification thin porcelain plate in a wet glaze spraying mode, so that the 'frame' defect is easy to occur, namely the glaze slurry cannot be uniformly applied on the surface of the ultra-large specification thin porcelain plate blank due to the action of surface tension, so that local glaze accumulation is caused, and the 'frame' defect is formed. Thirdly, if the wet glaze pouring form is adopted to apply the glaze slurry on the ultra-large thin porcelain plate, the defect of 'glaze curtain wire-drawing' is easy to occur, because the specification of the ultra-large thin porcelain plate is obviously larger than that of the traditional ceramic tile, when the wet glaze pouring application is adopted, the size of the glaze pouring equipment is inevitably enlarged, the glaze curtain with uniform distribution and components is difficult to form on the large glaze pouring equipment by the glaze slurry, the lump fake particles caused by a small amount of precipitation in the glaze slurry or the impurities left by the slurry pouring equipment are not completely cleaned, the defect of 'glaze curtain wire-drawing' is possibly caused during glaze pouring, then the local glaze-lacking defect is formed on the surface of the ultra-large thin porcelain plate blank, and the pit defect is formed after sintering.
The method is characterized in that glaze slurry for the ultra-large specification thin porcelain plate main body with reasonable rheological property is prepared by designing and adopting an ultra-large glaze spraying disc with the lower end face circular diameter not less than 2400mm, the problems are better solved, aiming at the defects of water ripple and a frame, the drawing is combined with the drawing 1 and the drawing 2, the ultra-large glaze spraying disc designed by the invention comprises a glaze spraying cover a and a glaze distributing device b, the glaze spraying cover a is composed of a glaze spraying cover main body cambered surface a1 and a glaze spraying cover end cambered surface a2, the glaze distributing device b is positioned at the upper center of the glaze spraying cover a, compared with the traditional spraying disc, the ultra-large glaze spraying disc is mainly designed and improved from three aspects, namely, the first ultra-large and ultra-large glaze spraying cover a has the lower end face circular diameter d not less than 2400mm, the requirement of a once-fired ultra-large specification thin porcelain plate blank for the size of the spraying disc for the glaze slurry application of the glaze slurry is designed to be a thin glaze slurry for the ultra-large thin porcelain plate blank with specification, the specification of the ultra-large glaze spraying cover with the specification of the specification ultra-large glaze slurry spraying, the specification of the arc face R1 is designed to be 5000mm, the end face of the glaze spraying cover equivalent specification of the ultra-large glaze slurry spraying cover b, the glaze slurry spraying cover equivalent specification of the arc face equivalent glaze slurry spraying cover equivalent specification of the arc face of the thin porcelain plate blank with the arc face equivalent specification of the thin glaze slurry spraying cover equivalent weight specification of the thin glaze slurry spraying the thin glaze slurry spraying, the specification of the thin glaze slurry spraying, the thin glaze slurry spraying cover equivalent weight specification of the thin glaze slurry spraying, the invention is designed by the invention, the.
And (3) respectively adopting the wrapped red ink and the wrapped yellow ink as the red ceramic ink and the yellow ceramic ink in the step I. The existing yellow ceramic ink is prepared by mixing praseodymium yellow pigment with organic solvent, etc., however, the praseodymium yellow pigment has serious fading in the firing process after being prepared into the yellow ceramic ink, and the yellow ceramic ink shows light color development and greenish hue. The existing red ceramic ink is actually reddish brown ceramic ink, and the reddish brown ink adopts an iron oxide red pigment as a coloring agent, so that the color development is dark and not bright. Therefore, the red ceramic coating ink and the yellow ceramic coating ink are used for replacing the red brown ceramic ink and the yellow ceramic coating ink in the prior art, and the zirconium silicate crystals are used for coating the corresponding pigments in the red ceramic coating ink and the yellow ceramic coating ink.
However, since the coated red ceramic ink and the coated yellow ceramic ink are prepared by a coating process, and a layer of zirconium silicate crystal is coated on the surface of the corresponding pigment, the particle size of the coated red ceramic ink and the particle size of the coated yellow ceramic ink are both larger than that of the common ink particles, so that the coated red ceramic ink and the coated yellow ceramic ink are easy to precipitate. In view of the above, the present invention provides an improvement in the ink path system of a digital ink jet printer. The former equipment china ink bucket does not set up agitating unit, and the pottery ink just begins the stirring after being taken out the ink horn by the china ink bucket, leads to often having a large amount of precipitations in the china ink bucket. According to the invention, the stirring device is additionally arranged in the ink barrel, and the ceramic ink forms a loop from bottom to top in the ink barrel by adopting upward rotary stirring, so that the precipitation phenomenon is effectively eliminated. In addition, the ink path pipeline is changed from a small caliber to a large caliber, the circulation of the ceramic ink loop is accelerated, three filtering devices are additionally arranged, the proportion of large pigment particles entering the ink box is reduced, and the loss of the spray head is reduced.
The firing system in the step J needs to be correspondingly adjusted according to the produced thin porcelain plate, particularly, after the thickness of the ultra-large thin porcelain plate is further reduced, in the temperature rise stage of the firing process, because the temperatures of all sections of the kiln are different and the specification of the ultra-large thin porcelain plate is very large, when the ultra-large thin porcelain plate is conveyed and heated in a wide kiln by using a roller rod, a large longitudinal temperature difference is easily formed in the advancing direction of the ultra-large thin porcelain plate, namely, the temperature of the part of the same ultra-large thin porcelain plate close to the advancing direction of the ultra-large thin porcelain plate is higher, the temperature of the part of the same ultra-large thin porcelain plate is lower in the advancing direction of the ultra-large thin porcelain plate, and is just opposite in the temperature reduction stage, so that the large longitudinal temperature difference is formed on the same ultra-large thin porcelain plate, and the front end and back end of the ultra-large thin porcelain plate are not shrunk uniformly, the deformation is formed, the invention can well improve the shrinkage uniformity and the flatness after firing of the ultra-large specification thin porcelain plate by properly prolonging the temperature rising transition zone and the temperature reducing transition zone, namely realizing balanced temperature rising/reducing through a temperature rising system from a preheating zone to a firing zone and a temperature reducing system from the firing zone to a cooling zone, adjusting the air pressure and the excess air coefficient in the kiln and the like.
In the cooling stage of the firing process, if the internal stress of the ultra-large thin porcelain plate exists, local cracking caused by nonuniform stress release of the ultra-large thin porcelain plate is very easy to cause, therefore, the valve opening of a quenching air pipe in a kiln quenching area cannot be over-extended, the quenching openings of the upper layer and the lower layer of the roller rod are approximately consistent, so that the temperature difference between the upper layer and the lower layer of the roller rod is reduced, the stress generated by inconsistent internal and external contraction in the cooling process of a blank body is reduced, and the defects of wind cracking and the like of the product are avoided, the valve opening of a heat pumping opening is required to be adjusted in a slow cooling area, so that the conversion of the crystal form of α -quartz to β -quartz is stable, and partial stress is released as much as possible.
As a further technical scheme, in the step J, the water absorption rate of the ultra-large thin porcelain plate semi-finished product is less than or equal to 0.5 percent, the failure strength is more than or equal to 800N, the modulus of rupture is more than or equal to 48MPa, and the volume weight is more than or equal to 2.25g/cm3。
And as a further technical scheme, after the edge grinding treatment in the step K, cutting a finished product to obtain the required specification and size of the finished product.
As a further technical scheme, after the edge grinding treatment in the step K, a polishing process is adopted for treatment. The surface of the ultra-large thin porcelain plate prepared by the method is subjected to required polishing treatment by changing the material quality and polishing process parameters of the grinding block, so that a semi-finished product of the ultra-large thin porcelain plate with a soft surface can be obtained, and the glossiness is 15-30 gloss units; or obtaining a semi-finished product of the ultra-large specification thin porcelain plate with a matte surface, wherein the glossiness is 5-15 gloss units.
And as a further technical scheme, in the step N, the pore size distribution range of the porous ceramic is 1 mu m-1 mm.
As a further technical scheme, the temperature control system in the step L can control the heating power of the graphene film, so that the temperature of the ultra-large thin ceramic plate with the electrothermal function is controlled to be between 30 and 50 ℃ when the ultra-large thin ceramic plate is stable, and the temperature control system is provided with safety protection devices such as overheating and overload to prevent the graphene film from being abnormal in the working process.
The ultra-large specification thin porcelain plate with the electric heating function produced by the invention has the following beneficial effects:
compared with the prior art which mostly adopts an anhydrous decoration process, the invention innovatively introduces the baking process into the production method of the ultra-large specification thin porcelain plate, and can solve the problems that the ultra-large specification thin porcelain plate blank is easy to damage and the like due to the adoption of the wet glaze pouring hydrous decoration process after the ultra-large specification thin porcelain plate blank is formed.
Compared with the existing decoration means and decoration effect of the thin porcelain plate, the invention innovatively introduces the baking process in the preparation method of the ultra-large thin porcelain plate, obviously improves the strength of the blank body of the ultra-large thin porcelain plate, and is suitable for the waterless decoration process and the water-containing decoration process, so that the decoration means and decoration effect are more abundant.
Compared with the traditional biscuit firing process, on one hand, the baking process has the advantages of lower temperature and shorter period, the baked ultra-large thin porcelain plate blank has certain strength and strong adsorption capacity to wet glaze slurry, and is suitable for wet glaze pouring and other water-containing decoration processes, and the biscuit firing process has relatively higher temperature and longer period, so that the adsorption capacity of the baked ultra-large thin porcelain plate blank to the wet glaze slurry is greatly weakened, and the wet glaze pouring decoration process is not facilitated; on the other hand, the baking temperature is lower, the period is shorter, the energy consumption of the kiln is lower, the production flow is quicker and more efficient, and the production cost is obviously reduced.
Compared with the traditional wet-process glaze pouring and applying mode, the invention prepares the glaze slurry for the ultra-large specification thin porcelain plate with reasonable rheological property by designing and adopting the ultra-large pouring disc with the end face circle diameter of the lower end not less than 2400mm, and better solves the defects of 'water ripple' and 'frame'; the invention strictly controls the working procedures of deironing, sieving, storing and the like of the glaze slurry for the ultra-large specification thin porcelain plate by optimizing the technological parameters such as flow speed, specific gravity, viscosity and the like of the glaze slurry for the ultra-large specification thin porcelain plate, and frequently cleans related glazing equipment such as an ultra-large spray tray, a glaze barrel and the like, thereby well solving the problem of 'glaze curtain wire pulling'.
The invention can reduce the large longitudinal temperature difference of the ultra-large specification thin porcelain plate in the kiln firing process and well improve the shrinkage uniformity and the flatness after firing of the ultra-large specification thin porcelain plate by properly prolonging the temperature rising transition zone and the temperature reducing transition zone, namely realizing balanced temperature rising/reducing through a temperature rising system from the preheating zone to the firing zone and a temperature reducing system from the firing zone to the cooling zone, adjusting the coefficients of air pressure and excess air in the kiln and the like. Through the valve opening of the quenching air pipe in the quenching area of the kiln and the valve opening of the hot air pumping opening in the quenching area, the temperature difference between the upper layer and the lower layer of the roller rod is controlled within 50-100 ℃, and the problem of cooling and cracking of the ultra-large thin porcelain plate is effectively solved.
According to the invention, one or two of porous ceramics and ceramic microspheres are used as a heat insulation layer, the graphene film provided with an electrode and a temperature control system is used as an electric heating layer, the produced ultra-large thin ceramic plate semi-finished product is used as a decorative layer, the ultra-large thin ceramic plate with the electric heating function is produced, the ultra-large thin ceramic plate is endowed with the excellent electric heating function, the problem of ice cold of the ceramic tile is really solved, the ceramic tile is suitable for the aspects of wall floors, cabinets, cabinet body decorative panels, hand washing tables and the like, especially when the ceramic tile is applied to table tops, the cooked food can be kept at the temperature of 30-50 ℃ through the temperature control system, and the whole home environment can achieve a warming effect when the ceramic tile is comprehensively applied.
Drawings
FIG. 1 is a side view of the oversized shower tray of the present invention;
the glaze spraying device comprises a glaze spraying cover, b glaze dividing device, c glaze spraying cover end arc surface width, d glaze spraying cover lower end surface circle diameter, R1 arc surface radius of glaze spraying cover main body arc surface, R2 arc surface radius of glaze spraying cover end arc surface, L1 tangent line at intersection point of glaze spraying cover main body arc surface and glaze spraying cover end arc surface, L2 horizontal line, α included angle of L1 tangent line at intersection point of glaze spraying cover main body arc surface and glaze spraying cover end arc surface and L2 horizontal line.
FIG. 2 is a drawing of an oversized tray-type glaze pouring cover part of the invention:
wherein a1 is the cambered surface of the main body of the glaze pouring cover, and a2 is the cambered surface of the end part of the glaze pouring cover.
Detailed Description
Specific embodiments are given below in conjunction with fig. 1.
Example 1
A. Preparing blank powder for the ultra-large thin porcelain plate according to a conventional method for later use;
B. preparing a ground glaze for an oversized thin porcelain plate according to a conventional method, and preparing a polishing glaze for an oversized thin porcelain plate with an anti-slip function according to the conventional method, wherein the polishing glaze comprises the chemical composition of SiO in percentage by weight2：45%、Al2O3：28%、CaO：4%、MgO：2%、K2O：3%、Na2O：4%、ZnO：1%、BaO：11%、ZrO2: 2 percent for standby;
C. distributing blank powder and performing die-free press molding: b, distributing the blank powder for the ultra-large thin porcelain plate prepared in the step A according to the designed pattern texture, and forming by a die-free compression forming process to obtain the ultra-large thin porcelain plate blank, wherein the bulk weight of the formed blank is 1.95g/cm3；
D. Automatic green body cutting: c, automatically cutting the blank of the ultra-large thin porcelain plate which is formed by die-free pressing in the step C to obtain the required specification and size of the blank;
E. drying the blank: d, drying the ultra-large specification thin porcelain plate blank subjected to automatic blank cutting in the step D according to a conventional method, wherein the drying temperature is 150 ℃;
F. baking: e, baking the ultra-large specification thin porcelain plate blank dried in the step E, and bakingThe baking temperature is 700 ℃, the baking period is 10min, and the volume weight of the baked ultra-large thin porcelain plate blank is 1.80g/cm3The modulus of rupture of the baked blank is 3.0 MPa;
G. applying the ground glaze for the ultra-large specification thin porcelain plate, namely applying the ground glaze for the ultra-large specification thin porcelain plate prepared in the step B on the surface of the blank of the ultra-large specification thin porcelain plate baked in the step F by adopting an ultra-large tray, wherein the diameter d of the circle of the lower end face of the ultra-large tray is 2400mm, the radius R1 of the arc surface a1 of the glaze spraying cover main body of the ultra-large tray is 4300mm, the radius R2 of the arc surface a2 of the end part of the glaze spraying cover is 240mm, the included angle α between the 387L 1 of the intersection point of the arc surface of the glaze spraying cover main body and the arc surface of the end part of the glaze spraying cover and the horizontal line L2 is 20 degrees, and the width c of the arc surface a 39;
H. and (3) drying again: drying the blank body of the ultra-large specification thin porcelain plate after the ground coat for the ultra-large specification thin porcelain plate is applied in the step G according to a conventional method, wherein the drying temperature is 180 ℃;
I. ink-jet printing: spraying ceramic ink on the ultra-large thin porcelain plate blank dried again in the step H by using a digital ink-jet printer according to a designed pattern, and matching with the pattern texture of the blank, so that the surface after ink-jet printing and the blank have similar texture and texture, and the temperature of the blank before ink-jet printing is 40 ℃;
J. applying polishing glaze for ultra-large specification thin porcelain plates: b, applying the polishing glaze for the ultra-large thin porcelain plate with the slip limiting function, which is prepared in the step B, on the surface of the ultra-large thin porcelain plate blank subjected to ink jet printing in the step I by adopting the ultra-large shower tray in the step G;
K. and (3) drying for the third time: drying the blank body of the ultra-large thin porcelain plate which is applied in the step J and has the anti-slip function and is polished with glaze for the ultra-large thin porcelain plate for the third time according to a conventional method;
l, firing: and D, placing the blank body of the ultra-large specification thin porcelain plate dried for the third time in a roller kiln for sintering, wherein the sintering temperature is 1200 ℃, the sintering period is 100min, obtaining the sintered ultra-large specification thin porcelain plate, and obtaining the sintered ultra-large specification thin porcelain plateThe water absorption of the plate is 0.29 percent, the failure strength is 810N, the modulus of rupture is 48MPa, and the volume weight is 2.25g/cm3；
M, edging: and D, utilizing conventional edging processing equipment to carry out edging treatment on the ultra-large specification thin porcelain plate prepared in the step L to prepare a semi-finished product of the ultra-large specification thin porcelain plate, wherein the specification of the semi-finished product is 1.6m multiplied by 4.8m (the upper surface area is 7.68 m)2) 6mm in thickness;
n, use porous ceramic as the insulating layer, porous ceramic aperture distribution range is 5~1000 mu M, with sealed glue at insulating layer surface composite electric heat layer, the electric heat layer is the graphite alkene film that is provided with electrode and temperature control system, at electric heat layer surface composite decorative layer, the decorative layer is the thin porcelain board semi-manufactured goods of super large specification of step M preparation, finally, produces the thin porcelain board of super large specification that has the electric heat function.
Example 2
A. Preparing blank powder for the ultra-large thin porcelain plate according to a conventional method for later use;
B. preparing a ground glaze for an oversized thin porcelain plate according to a conventional method, and preparing a polishing glaze for an oversized thin porcelain plate with an anti-slip function according to the conventional method, wherein the polishing glaze comprises the chemical composition of SiO in percentage by weight2：50%、Al2O3：20%、CaO：8%、MgO：3%、K2O：1%、Na2O：1%、ZnO：2%、BaO：13%、ZrO2: 2 percent, introducing high-fire-degree frits into the polishing glaze for later use;
C. distributing blank powder and performing die-free press molding: b, distributing the blank powder for the ultra-large thin porcelain plate prepared in the step A according to the designed pattern texture, and forming by a die-free compression forming process to obtain the ultra-large thin porcelain plate blank, wherein the bulk weight of the formed blank is 2.10g/cm3；
D. Automatic green body cutting: c, automatically cutting the blank of the ultra-large thin porcelain plate which is formed by die-free pressing in the step C to obtain the required specification and size of the blank;
E. drying the blank: d, drying the ultra-large specification thin porcelain plate blank subjected to automatic blank cutting in the step D according to a conventional method, wherein the drying temperature is 180 ℃;
F. baking: e, baking the ultra-large thin porcelain plate blank dried in the step E, wherein the baking temperature is 800 ℃, the baking period is 5min, and the volume weight of the baked ultra-large thin porcelain plate blank is 1.90g/cm3The modulus of rupture of the baked blank is 4.0 MPa;
G. applying the ground glaze for the ultra-large thin porcelain plate, namely applying the ground glaze for the ultra-large thin porcelain plate prepared in the step B on the surface of the blank of the ultra-large thin porcelain plate baked in the step F by using an ultra-large tray, wherein the diameter d of the end face circle of the lower end of the ultra-large tray is 2700mm, the arc radius R1 of the arc surface a1 of the glaze spraying cover main body of the ultra-large tray is 5000mm, the arc radius R2 of the arc surface a2 of the end part of the glaze spraying cover is 180mm, the included angle α between the line 387L 1 at the intersection point of the arc surface of the glaze spraying cover main body and the arc surface of the end part of the glaze spraying cover and the horizontal line L2 is 17 degrees, and the width c of the arc surface a;
H. and (3) drying again: drying the blank body of the ultra-large thin porcelain plate after the ground coat for the ultra-large thin porcelain plate is applied in the step G according to a conventional method, wherein the drying temperature is 200 ℃;
I. ink-jet printing: spraying ceramic ink on the ultra-large thin ceramic plate blank dried again in the step H by using a digital ink-jet printer according to a designed pattern, matching with the pattern texture of the blank, so that the surface after ink-jet printing and the blank have similar texture, wherein the red ceramic ink and the yellow ceramic ink respectively adopt coated red ceramic ink and coated yellow ceramic ink, and the temperature of the blank before ink-jet printing is 70 ℃;
J. applying polishing glaze for ultra-large specification thin porcelain plates: b, applying the polishing glaze for the ultra-large thin porcelain plate with the slip limiting function, which is prepared in the step B, on the surface of the ultra-large thin porcelain plate blank subjected to ink jet printing in the step I by adopting the ultra-large shower tray in the step G;
K. and (3) drying for the third time: drying the blank body of the ultra-large thin porcelain plate which is applied in the step J and has the anti-slip function and is polished with glaze for the ultra-large thin porcelain plate for the third time according to a conventional method;
l, firing: and D, placing the blank body of the ultra-large thin porcelain plate dried for the third time in a roller kiln for sintering, wherein the sintering temperature is 1250 ℃, the sintering period is 60min, and obtaining the sintered ultra-large thin porcelain plate, wherein the water absorption of the sintered ultra-large thin porcelain plate is 0.1%, the breaking strength is 1010N, the breaking modulus is 55MPa, and the volume weight is 2.36g/cm3；
M, edging: and D, utilizing conventional edging processing equipment to carry out edging treatment on the ultra-large specification thin porcelain plate prepared in the step L to prepare a semi-finished product of the ultra-large specification thin porcelain plate, wherein the specification of the semi-finished product is 1.6m multiplied by 3.2m (the upper surface area is 5.12 m)2) 5.5mm in thickness;
n, use porous ceramic as the insulating layer, porous ceramic aperture distribution range is 10~800 mu M, with sealed glue at insulating layer surface composite electric heat layer, the electric heat layer is the graphite alkene film that is provided with electrode and temperature control system, at electric heat layer surface composite decorative layer, the decorative layer is the thin porcelain board semi-manufactured goods of super large specification of step M preparation, finally, produces the thin porcelain board of super large specification that has the electric heat function.
Example 3
A. Preparing blank powder for the ultra-large thin porcelain plate according to a conventional method for later use;
B. preparing a ground glaze for an oversized thin porcelain plate according to a conventional method, and preparing a polishing glaze for an oversized thin porcelain plate with an anti-slip function according to the conventional method, wherein the polishing glaze comprises the chemical composition of SiO in percentage by weight2：47%、Al2O3：24%、CaO：0%、MgO：0%、K2O：5%、Na2O：5%、ZnO：0%、BaO：15%、ZrO2: 4 percent, corundum is introduced into the polishing glaze for standby;
C. distributing blank powder and performing die-free press molding: b, distributing the blank powder for the ultra-large thin porcelain plate prepared in the step A according to the designed pattern texture, and forming by a die-free compression forming process to obtain the ultra-large thin porcelain plate blankThe volume weight of the molded blank is 2.00g/cm3；
D. Automatic green body cutting: c, automatically cutting the blank of the ultra-large thin porcelain plate which is formed by die-free pressing in the step C to obtain the required specification and size of the blank;
E. drying the blank: d, drying the ultra-large specification thin porcelain plate blank subjected to automatic blank cutting in the step D according to a conventional method, wherein the drying temperature is 200 ℃;
F. baking: e, baking the ultra-large thin porcelain plate blank dried in the step E, wherein the baking temperature is 500 ℃, the baking period is 15min, and the volume weight of the baked ultra-large thin porcelain plate blank is 1.87g/cm3The modulus of rupture of the baked blank is 3.5 MPa;
G. applying the ground glaze for the ultra-large thin porcelain plate, namely applying the ground glaze for the ultra-large thin porcelain plate prepared in the step B on the surface of the blank of the ultra-large thin porcelain plate baked in the step F by using an ultra-large tray, wherein the diameter d of the circle of the lower end face of the ultra-large tray is 2450mm, the arc radius R1 of the arc surface a1 of the glaze spraying cover main body of the ultra-large tray is 4800mm, the arc radius R2 of the arc surface a2 of the end part of the glaze spraying cover is 220mm, the included angle α between the tangent line L1 at the intersection point of the arc surface of the glaze spraying cover main body and the arc surface of the end part of the glaze spraying cover and the horizontal line L2 is 10 degrees, and the width c of the arc surface a 39;
H. and (3) drying again: drying the thin porcelain plate blank body subjected to the ground glaze application of the thin porcelain plate in the step G again according to a conventional method, wherein the drying temperature is 150 ℃;
I. ink-jet printing: spraying ceramic ink on the ultra-large thin ceramic plate blank dried again in the step H by using a digital ink-jet printer according to a designed pattern, matching with the pattern texture of the blank, so that the surface after ink-jet printing and the blank have similar texture, wherein the red ceramic ink and the yellow ceramic ink respectively adopt coated red ceramic ink and coated yellow ceramic ink, and the temperature of the blank before ink-jet printing is 55 ℃;
J. applying polishing glaze for ultra-large specification thin porcelain plates: b, applying the polishing glaze for the ultra-large thin porcelain plate with the slip limiting function, which is prepared in the step B, on the surface of the ultra-large thin porcelain plate blank subjected to ink jet printing in the step I by adopting the ultra-large shower tray in the step G;
K. and (3) drying for the third time: drying the blank body of the ultra-large thin porcelain plate which is applied in the step J and has the anti-slip function and is polished with glaze for the ultra-large thin porcelain plate for the third time according to a conventional method;
l, firing: and D, placing the blank body of the ultra-large thin porcelain plate dried for the third time in the step K into a roller kiln for sintering, wherein the sintering temperature is 1150 ℃, the sintering period is 150min, and obtaining the sintered ultra-large thin porcelain plate, the water absorption of the sintered ultra-large thin porcelain plate is 0.07%, the breaking strength is 1216N, the modulus of rupture is 50MPa, and the volume weight is 2.39g/cm3；
M, edging and polishing: and D, utilizing conventional edging and polishing processing equipment to carry out edging and polishing treatment on the ultra-large thin porcelain plate prepared in the step L to prepare a semi-finished product of the ultra-large thin porcelain plate with a soft surface effect on the surface, wherein the specification of the semi-finished product is 0.9m multiplied by 1.8m (the upper surface area is 1.62 m)2) Thickness of 5.8mm and glossiness of 28 gloss units;
n, use porous ceramic as the insulating layer, porous ceramic aperture distribution range is 50~500 mu M, with sealed glue at insulating layer surface composite electric heat layer, the electric heat layer is the graphite alkene film that is provided with electrode and temperature control system, at electric heat layer surface composite decorative layer, the decorative layer is the thin porcelain board semi-manufactured goods of super large specification of step M preparation, finally, produces the thin porcelain board of super large specification that has the electric heat function.
Example 4
A. Preparing blank powder for the ultra-large thin porcelain plate according to a conventional method for later use;
B. preparing a ground glaze for an oversized thin porcelain plate according to a conventional method, and preparing a polishing glaze for an oversized thin porcelain plate with an anti-slip function according to the conventional method, wherein the polishing glaze comprises the chemical composition of SiO in percentage by weight2：48%、Al2O3：26%、CaO：5%、MgO：1%、K2O：2%、Na2O：3%、ZnO：5%、BaO：10%、ZrO2: 0 percent of high-fire-degree fusion cake and corundum are introduced into the polishing glaze for standby;
C. distributing blank powder and performing die-free press molding: distributing the blank powder for the ultra-large thin porcelain plate in the step A according to the designed pattern texture, and molding by a die-free compression molding process to obtain the ultra-large thin porcelain plate blank, wherein the bulk weight of the molded blank is 2.05g/cm3；
D. Automatic green body cutting: c, automatically cutting the blank of the ultra-large thin porcelain plate which is formed by die-free pressing in the step C to obtain the required specification and size of the blank;
E. drying the blank: d, drying the ultra-large specification thin porcelain plate blank subjected to automatic blank cutting in the step D according to a conventional method, wherein the drying temperature is 220 ℃;
F. baking: e, baking the ultra-large thin porcelain plate blank dried in the step E, wherein the baking temperature is 650 ℃, the baking period is 8min, and the volume weight of the baked ultra-large thin porcelain plate blank is 1.85g/cm3The modulus of rupture of the baked blank is 3.3 MPa;
G. applying the ground glaze for the ultra-large thin porcelain plate, namely applying the ground glaze for the ultra-large thin porcelain plate prepared in the step B on the surface of the blank of the ultra-large thin porcelain plate baked in the step F by using an ultra-large tray, wherein the diameter d of the end face circle of the lower end of the ultra-large tray is 2600mm, the arc radius R1 of the arc surface a1 of the glaze spraying cover main body of the ultra-large tray is 4500mm, the arc radius R2 of the arc surface a2 of the end part of the glaze spraying cover is 200mm, the included angle α between the 38732 tangent line at the intersection point of the arc surface of the glaze spraying cover main body and the arc surface of the end part of the glaze spraying cover and the horizontal line L2 is 13 degrees, and the width c of the arc surface a 39;
H. and (3) drying again: drying the blank body of the ultra-large thin porcelain plate after the ground coat for the ultra-large thin porcelain plate is applied in the step G according to a conventional method, wherein the drying temperature is 170 ℃;
I. ink-jet printing: spraying ceramic ink on the ultra-large thin porcelain plate blank dried again in the step H by using a digital ink-jet printer according to a designed pattern, and matching with the pattern texture of the blank, so that the surface after ink-jet printing and the blank have similar texture and texture, and the temperature of the blank before ink-jet printing is 60 ℃;
J. applying polishing glaze for ultra-large specification thin porcelain plates: b, applying the polishing glaze for the ultra-large thin porcelain plate with the slip limiting function, which is prepared in the step B, on the surface of the ultra-large thin porcelain plate blank subjected to ink jet printing in the step I by adopting the ultra-large shower tray in the step G;
K. and (3) drying for the third time: drying the blank body of the ultra-large thin porcelain plate which is applied in the step J and has the anti-slip function and is polished with glaze for the ultra-large thin porcelain plate for the third time according to a conventional method;
l, firing: and D, placing the ultra-large specification thin porcelain plate blank dried for the third time in the step K into a roller kiln for sintering, wherein the sintering temperature is 1180 ℃, the sintering period is 120min, and the sintered ultra-large specification thin porcelain plate is prepared, the water absorption rate of the sintered ultra-large specification thin porcelain plate is 0.25%, the breaking strength is 880N, the fracture modulus is 60MPa, and the volume weight is 2.32g/cm3；
M, edging and polishing: and D, utilizing conventional edging and polishing processing equipment to carry out edging and polishing treatment on the ultra-large thin porcelain plate prepared in the step L to prepare a semi-finished product of the ultra-large thin porcelain plate with a matte effect on the surface, wherein the specification of the semi-finished product is 1.6m multiplied by 5.2m (the upper surface area is 8.32 m)2) The thickness is 4.5mm, and the glossiness is 8 gloss units;
and N, compounding an electric heating layer on the surface of the heat insulation layer by using ceramic microspheres as the heat insulation layer and using sealant, wherein the electric heating layer is provided with an electrode and a temperature control system and is a graphene film, compounding a decorative layer on the surface of the electric heating layer, and the decorative layer is a semi-finished product of the ultra-large thin porcelain plate prepared in the step M, so that the ultra-large thin porcelain plate with the electric heating function is finally produced.
Example 5
A. Preparing blank powder for the ultra-large thin porcelain plate according to a conventional method for later use;
B. preparing ultra-large specification thin porcelain according to conventional methodPreparing a base glaze for a plate, and preparing a polishing glaze for an ultra-large thin porcelain plate with an anti-slip function by a conventional method, wherein the polishing glaze comprises the chemical composition of SiO in percentage by weight2：46%、Al2O3：22%、CaO：3%、MgO：1%、K2O：4%、Na2O：2%、ZnO：3%、BaO：14%、ZrO2: 5% for standby;
C. distributing blank powder and performing die-free press molding: b, distributing the blank powder for the ultra-large thin porcelain plate prepared in the step A according to the designed pattern texture, and forming by a die-free compression forming process to obtain the ultra-large thin porcelain plate blank, wherein the bulk weight of the formed blank is 1.98g/cm3；
D. Automatic green body cutting: c, automatically cutting the blank of the ultra-large thin porcelain plate which is formed by die-free pressing in the step C to obtain the required specification and size of the blank;
E. drying the blank: d, drying the ultra-large specification thin porcelain plate blank subjected to automatic blank cutting in the step D according to a conventional method, wherein the drying temperature is 175 ℃;
F. baking: e, baking the ultra-large thin porcelain plate blank dried in the step E, wherein the baking temperature is 750 ℃, the baking period is 11min, and the volume weight of the baked ultra-large thin porcelain plate blank is 1.83g/cm3The modulus of rupture of the baked blank is 5.1 MPa;
G. applying the ground glaze for the ultra-large thin porcelain plate, namely applying the ground glaze for the ultra-large thin porcelain plate prepared in the step B on the surface of the blank of the ultra-large thin porcelain plate baked in the step F by using an ultra-large tray, wherein the diameter d of the circle of the lower end face of the ultra-large tray is 2550mm, the radius R1 of the arc surface a1 of the glaze spraying cover body of the ultra-large tray is 4700mm, the radius R2 of the arc surface a2 of the end part of the glaze spraying cover is 210mm, the included angle α between the tangent line L1 at the intersection point of the arc surface of the glaze spraying cover body and the arc surface of the end part of the glaze spraying cover and the horizontal line L2 is 15 degrees, and the width c of the arc surface a2 of the;
H. and (3) drying again: drying the blank body of the ultra-large thin porcelain plate after the ground coat for the ultra-large thin porcelain plate is applied in the step G according to a conventional method, wherein the drying temperature is 190 ℃;
I. ink-jet printing: spraying ceramic ink on the ultra-large thin porcelain plate blank dried again in the step H by using a digital ink-jet printer according to a designed pattern, and matching with the pattern texture of the blank, so that the surface after ink-jet printing and the blank have similar texture and texture, and the temperature of the blank before ink-jet printing is 65 ℃;
J. applying polishing glaze for ultra-large specification thin porcelain plates: b, applying the polishing glaze for the ultra-large thin porcelain plate with the slip limiting function, which is prepared in the step B, on the surface of the ultra-large thin porcelain plate blank subjected to ink jet printing in the step I by adopting the ultra-large shower tray in the step G;
K. and (3) drying for the third time: drying the blank body of the ultra-large thin porcelain plate which is applied in the step J and has the anti-slip function and is polished with glaze for the ultra-large thin porcelain plate for the third time according to a conventional method;
l, firing: and D, placing the blank body of the ultra-large thin porcelain plate dried for the third time in a roller kiln for sintering, wherein the sintering temperature is 1220 ℃, the sintering period is 80min, and obtaining the sintered ultra-large thin porcelain plate, the water absorption of the sintered ultra-large thin porcelain plate is 0.09%, the breaking strength is 930N, the breaking modulus is 63MPa, and the bulk weight is 2.37g/cm3；
M, edging: and D, edging the ultra-large thin porcelain plate prepared in the step L by utilizing conventional edging processing equipment to prepare a semi-finished product of the ultra-large thin porcelain plate, wherein the specification of the semi-finished product is 1.6m multiplied by 4.0m (the upper surface area of the semi-finished product is 6.40 m)2) The thickness is 3 mm;
n, use porous ceramic as the insulating layer, porous ceramic aperture distribution range is 30~700 mu M, with sealed glue at insulating layer surface composite electric heat layer, the electric heat layer is the graphite alkene film that is provided with electrode and temperature control system, at electric heat layer surface composite decorative layer, the decorative layer is the thin porcelain board semi-manufactured goods of super large specification of step M preparation, finally, produces the thin porcelain board of super large specification that has the electric heat function.
Although the present invention has been described in detail with reference to the embodiments, it should be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present invention.

Claims (14)

1. A production method of an ultra-large specification thin porcelain plate with an electric heating function is characterized by comprising the following steps:
A. preparing blank powder for the ultra-large thin porcelain plate according to a conventional method for later use;
B. preparing a ground glaze for an oversized thin porcelain plate according to a conventional method, and preparing a polishing glaze for an oversized thin porcelain plate with an anti-slip function according to the conventional method, wherein the polishing glaze comprises the chemical composition of SiO in percentage by weight2：45%~50%、Al2O3：20%~28%、CaO：0~8%、MgO：0~3%、K2O：1%~5%、Na2O：1%~5%、ZnO：0~5%、BaO：10%~15%、ZrO2: 0-5% for standby;
C. distributing blank powder and performing die-free press molding: b, distributing the blank powder for the ultra-large thin porcelain plate prepared in the step A according to the designed pattern texture, and forming by a die-free compression forming process to obtain the ultra-large thin porcelain plate blank, wherein the bulk weight of the formed blank is more than or equal to 1.95g/cm3；
D. Automatic green body cutting: c, automatically cutting the blank of the ultra-large thin porcelain plate which is formed by die-free pressing in the step C to obtain the required specification and size;
E. drying the blank: d, drying the ultra-large specification thin porcelain plate blank subjected to automatic blank cutting in the step D according to a conventional method;
F. baking: e, baking the ultra-large thin porcelain plate blank dried in the step E, wherein the baking temperature is 500-800 ℃, the baking period is 5-15 min, and the volume weight of the baked thin porcelain plate blank is more than or equal to 1.80g/cm3The modulus of rupture of the baked green body is more than or equal to 3.0 MPa;
G. applying a base glaze for the ultra-large specification thin porcelain plate: b, applying the ground glaze for the ultra-large thin porcelain plate prepared in the step B on the surface of the ultra-large thin porcelain plate blank baked in the step F by using an ultra-large spraying disc, wherein the diameter of the end face circle of the lower end of the ultra-large spraying disc is more than or equal to 2400 mm;
H. and (3) drying again: drying the blank body of the ultra-large specification thin porcelain plate after the ground coat for the ultra-large specification thin porcelain plate is applied in the step G again according to a conventional method;
I. ink-jet printing: spraying ceramic ink on the ultra-large thin porcelain plate blank dried again in the step H by using a digital ink-jet printer according to a designed pattern, and matching with the pattern texture of the blank, so that the surface after ink-jet printing and the blank have similar texture and texture, and the temperature of the blank before ink-jet printing is 40-70 ℃;
J. applying polishing glaze for ultra-large specification thin porcelain plates: b, applying the polishing glaze for the ultra-large thin porcelain plate with the slip limiting function, which is prepared in the step B, on the surface of the ultra-large thin porcelain plate blank subjected to ink jet printing in the step I by adopting the ultra-large shower tray in the step G;
K. and (3) drying for the third time: drying the blank body of the ultra-large thin porcelain plate which is applied in the step J and has the anti-slip function and is polished with glaze for the ultra-large thin porcelain plate for the third time according to a conventional method;
l, firing: placing the ultra-large thin porcelain plate blank dried for the third time in the step K into a roller kiln for sintering, wherein the sintering temperature is 1150-1250 ℃, and the sintering period is 60-150 min;
m, edging: and D, utilizing conventional edging processing equipment to carry out edging treatment on the fired ultra-large specification thin porcelain plate obtained in the step L to obtain a semi-finished product of the ultra-large specification thin porcelain plate, wherein the thickness of the semi-finished product is less than or equal to 6mm, and the upper surface area of the semi-finished product is more than or equal to 1.62m2；
And N, taking one or two of porous ceramics and ceramic microspheres as a heat insulation layer, compounding an electric heating layer on the surface of the heat insulation layer by using sealant, compounding a decorative layer on the surface of the electric heating layer, wherein the electric heating layer is a graphene film provided with an electrode and a temperature control system, and the decorative layer is a semi-finished product of the ultra-large thin porcelain plate prepared in the step M, and finally producing the ultra-large thin porcelain plate finished product with an electric heating function.
2. The method for producing an extra-large-sized thin porcelain plate having an electrothermal function as claimed in claim 1, wherein: and B, introducing high-fire-degree frits and/or corundum materials into the polishing glaze for the ultra-large thin porcelain plate with the anti-slip function.
3. The method for producing an extra-large-sized thin porcelain plate having an electrothermal function as claimed in claim 1, wherein: in the step C, the volume weight difference between any two parts of the blank of the ultra-large thin porcelain plate in the same sheet is less than or equal to 0.1g/cm3。
4. The method for producing an extra-large-sized thin porcelain plate having an electrothermal function as claimed in claim 1, wherein: and G, the arc radius of the arc surface of the glaze pouring cover main body of the oversized glaze pouring tray is 4300-5000 mm, and the arc radius of the arc surface of the end part of the glaze pouring cover is 180-240 mm.
5. The method for producing an extra-large-sized thin porcelain plate having an electrothermal function as claimed in claim 1, wherein: and G, forming an included angle of 10-20 degrees between a tangent line at the intersection point of the arc surface of the glaze pouring cover body of the oversized pouring tray and the arc surface of the end part of the glaze pouring cover and a horizontal line.
6. The method for producing an extra-large-sized thin porcelain plate having an electrothermal function as claimed in claim 1, wherein: and G, the width of the cambered surface at the end part of the glaze spraying cover of the oversized spraying disc is 80-120 mm.
7. The method for producing an extra-large-sized thin porcelain plate having an electrothermal function as claimed in claim 1, wherein: and (3) respectively adopting the wrapped red ceramic ink and the wrapped yellow ceramic ink as the red ceramic ink and the yellow ceramic ink of the ceramic ink in the step (I).
8. The method for producing an extra-large-sized thin porcelain plate having an electrothermal function as claimed in claim 1, wherein: in the step J, the water absorption rate of the ultra-large thin porcelain plate semi-finished product is less than or equal to 0.5 percent, the failure strength is more than or equal to 800N, the breaking modulus is more than or equal to 48MPa, and the volume weight is more than or equal to 2.25g/cm3。
9. The method for producing an extra-large-sized thin porcelain plate having an electrothermal function as claimed in claim 1, wherein: and D, after the edging treatment in the step K, cutting a finished product to obtain the required specification and size of the finished product.
10. The method for producing an extra-large-sized thin porcelain plate having an electrothermal function as claimed in claim 1, wherein: and D, after the edging treatment in the step K, adopting a polishing process for treatment.
11. The method for producing an extra-large-sized thin porcelain plate having an electrothermal function according to claim 10, wherein: after the polishing process is adopted for treatment, the prepared ultra-large thin porcelain plate semi-finished product with the soft surface has the glossiness of 15-30 gloss units.
12. The method for producing an extra-large-sized thin porcelain plate having an electrothermal function according to claim 10, wherein: after the polishing process is adopted for treatment, the prepared semi-finished product of the ultra-large thin porcelain plate with the matte surface has the glossiness of 5-15 gloss units.
13. The method for producing an extra-large-sized thin porcelain plate having an electrothermal function as claimed in claim 1, wherein: and D, in the step N, the pore size distribution range of the porous ceramic is 1 mu m-1 mm.
14. The extra-large thin porcelain plate product with an electrothermal function produced by the method for producing an extra-large thin porcelain plate with an electrothermal function according to any one of claims 1 to 13.
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