CN111037729B

CN111037729B - Material distribution equipment, material distribution method and preparation method for full-body granite ceramic tile

Info

Publication number: CN111037729B
Application number: CN201911215520.3A
Authority: CN
Inventors: 张松竹; 吴文武; 黄玲艳; 周勇; 陈文新; 朱晨华; 王帆
Original assignee: Guangdong Qingyuan Monalisa Building Ceramic Co ltd; Monalisa Group Co Ltd
Current assignee: Guangdong Qingyuan Monalisa Building Ceramic Co ltd; Monalisa Group Co Ltd
Priority date: 2019-12-02
Filing date: 2019-12-02
Publication date: 2021-05-04
Anticipated expiration: 2039-12-02
Also published as: CN111037729A

Abstract

The invention discloses a material distribution device, a material distribution method and a preparation method for a full-body granite ceramic tile. The distribution equipment for the whole-body granite ceramic tile is characterized by comprising a hopper for storing toner, a micro cylinder gate for controlling the opening according to the color depth of a surface pattern so as to control the discharging position and the discharging amount of the toner, a distribution belt for containing the toner for discharging, and a feeding belt for conveying the toner to a press forming belt.

Description

Material distribution equipment, material distribution method and preparation method for full-body granite ceramic tile

Technical Field

The invention belongs to the field of ceramic building materials, and particularly relates to a material distribution device, a material distribution method and a preparation method for a full-body granite ceramic tile.

Background

The granite-like products on the market at present are only pressed into green bricks by mixing powder materials with different colors and matching with a mould, and the surfaces of the green bricks are decorated by glazing, ink jetting and dry particle spraying; the product has thin coloring layer on the surface, surface patterns are easy to lose after being worn and expose out of the base blank, and the patterns of the base blank are different from those of the surface layer after being used for a long time, so that the product is seriously influenced in appearance, and the application range is narrow. The base blank of the product is subjected to color matching by selecting main surface hues, preparing different toners and uniformly mixing, a large number of slurry tanks and powder tanks are required to be matched with the base blank, huge waste can be caused in the product conversion process, the base color texture is limited to be speckled, and the powder materials with different colors are uniformly mixed to ensure that the appearance sandstone does not have texture, so that the selection range of patterns of granite products is narrow, and the whole product with complex surface texture cannot be produced.

Disclosure of Invention

Aiming at the defects, the invention aims to provide a material distribution device, a material distribution method and a preparation method for a full-body granite ceramic tile.

In a first aspect, the invention provides a distribution device for a full-body granite ceramic tile, comprising a hopper for storing toner, a micro valve cylinder for controlling the toner blanking position and the blanking amount according to the color depth of a surface pattern through the opening degree of a micro cylinder gate, a distribution belt for containing the toner blanking, and a feeding belt for conveying the toner to a press forming belt.

Preferably, the micro cylinders are arranged in parallel, and each row is more than 60-90 micro cylinders; preferably, the discharge area controlled by each micro cylinder is (6-25) × (6-25) mm.

Preferably, the cloth belt and the feeding belt are arranged in a height mode, wherein the cloth belt is arranged on the upper portion, and the feeding belt is arranged on the lower portion.

Preferably, the material distribution equipment further comprises an automatic pressurizing air storage cylinder for stabilizing the air pressure for the micro air cylinder and the opening degree of the gate.

According to the distribution method for preparing the through granite ceramic tile by using the distribution equipment, the color and the blanking position of the toner are selected according to a graphic file for controlling a micro-cylinder gate, and the opening time of the micro-cylinder gate is controlled according to the color depth change of the texture of the graphic file, so that the toner is stacked and distributed on a distribution belt, and the through granite pattern texture effect with the color and texture surfaces consistent with the interior is obtained.

Preferably, the speed ratio of the cloth belt to the feeding belt is 25: 25-25: 33; preferably, the speed of the cloth belt is 15-30 Hz of the frequency of a belt motor, and the speed of the feeding belt is 27-33 Hz.

Preferably, the thickness of the cloth is 5-30 mm. In the case where the present invention is not specifically described, the cloth thickness refers to the thickness of the toner after stacking the cloth on the cloth belt.

In a third aspect, the invention also provides a preparation method of the whole granite ceramic tile, which comprises the following steps: (1) distributing toner by using any one of the above distributing methods; (2) pressing, molding and sintering to obtain the whole granite ceramic tile.

Preferably, the toner includes a base powder and a colorant. The raw material of the basic powder comprises high-whiteness ball soil with the mass fraction of 20-30%; preferably, the chemical composition of the base powder material comprises: by mass percentage, the loss on ignition is 3.5-5.5%, and SiO is₂ 66.0～70.0％，Al₂O₃ 18.0～20.0％，Fe₂O₃ 0.3～0.5％，TiO₂ 0.1～0.3％，CaO 0.2～0.7％，MgO 0.3～0.8％，K₂O 1.7～2.7％，Na₂2.8-3.8% of O; more preferably, the base powder further comprises a special effect reinforcing agent with the addition amount of 0.3-0.5%. In the invention, the main component of the special effect reinforcing agent is a copolymer organic high polymer material of carboxylic acid and sodium sulfonate.

Preferably, the grain composition of the base powder is as follows: more than 30 meshes: 5-15%, 30-60 mesh: not less than 75%, 60-80 mesh: less than or equal to 5 percent, and the content of 80 meshes is as follows: less than or equal to 5 percent.

Preferably, the surface of the green body after the compression molding is subjected to ink-jet decoration.

Preferably, dry glaze is applied on the surface of the blank after ink jetting. Preferably, the specific gravity of the dry granular glaze can be 1.28-1.35, and the application amount of the dry granular glaze is 170-230 g/m²。

Preferably, the firing temperature is 1180-1200 ℃, and the firing period is 60-70 min.

The granite series products produced by the invention have completely consistent designed textures on the bottom and the surface of the ceramic brick, have clear textures, and show the stacking effect like volcanic lava.

Drawings

FIG. 1 is an XRD pattern of 03 water-washed clay.

FIG. 2 is an XRD pattern of a QX washed clay.

FIG. 3 XRD pattern of high whiteness ball clay.

FIG. 4 is an XRD pattern of Zhongshan mud.

FIG. 5 is a comparison of the strength of the powder material under different work materials.

FIG. 6 is a graph of the effect of chemical feed addition on flow rate.

FIG. 7 shows the situation of powder sticking on the wall of the exhaust air of the powder feeding box.

FIG. 8 shows the situation of powder sticking to the wall when the powder box is not used for exhausting air.

FIG. 9 is a schematic view of a digital material distribution system, wherein 1-hopper, 2-micro cylinder gate, 3-material distribution belt, and 4-material feeding belt.

FIG. 10 is a schematic view of a microcylinder gate with 1-hopper, 5-gate, 6-cylinder, 7-gas tube.

Fig. 11 is a cloth flow chart.

Fig. 12 is an example of a graphic file for controlling the micro-cylinder gate, and fig. A, B, C, D is an example of a graphic file for the layer A, B, C, D, respectively.

FIG. 13 is a schematic view of an air reservoir with an 8-gauge, 9-compressed air inlet, and 10-compressed air outlet.

FIG. 14 is a flow chart of a process for producing an exemplary all-body granite ceramic tile of the present invention.

FIG. 15 is a graph of an exemplary firing profile of the present invention.

FIG. 16 is an elevation view of an exemplary all-body granite ceramic tile of the present invention.

FIG. 17 is a side view of an exemplary all-body granite ceramic tile of the present invention.

Detailed Description

The present invention is further illustrated by the following examples, which are to be understood as merely illustrative and not restrictive. The following percentages are by mass unless otherwise specified. In the case where the present invention is not specifically described, the "gate" may be referred to as a "gate opening".

In order to meet the requirements of the home decoration industry, the invention enables standard toner to be superposed on a cloth belt (in an imitation 3D printing mode) by controlling the opening time of gates of different micro cylinders when the product is distributed according to the design requirements of patterns of granite products, and distributes a product with the through effect that the surface of color and texture is consistent with the inside. The product meets the household identification requirements and various decoration requirements of modern people, and has excellent physical and chemical properties.

The following description shows a method for distributing and preparing the whole granite by using the distribution apparatus of the present invention, according to fig. 14.

Firstly, mixing raw materials of a blank according to a formula, carrying out ball milling, sieving to remove iron, preparing slurry, carrying out color matching, spraying powder and ageing to obtain the toner. In some embodiments, the fineness of the slurry may be 0.6-0.8% (250 mesh screen). The flow rate of the slurry may be 40-70 s. The specific gravity of the slurry may be 1.68 to 1.71. The moisture content of the toner is controlled to 7.0-8.0%.

The material distribution method for realizing the blanking of the micro cylinder gate requires that the toner has extremely strong plasticity and reasonable grain composition. The invention selects high-strength clay and high-strength bentonite and introduces a special effect reinforcing agent by testing and screening plastic raw materials, thereby improving the strength of powder, increasing the fluidity of the powder and improving the forming performance. The improved powder material is smooth, stable and controllable in blanking, and the required patterns can be realized.

The toner may include a base powder and a colorant. The pigment can be added in the process of preparing the slurry so as to prepare the color paste.

In some embodiments, the chemical composition of the base powder (the base powder other than the colorant) includes: by mass percentage, the loss on ignition is 3.5-5.5%, and SiO is₂ 66.0～70.0％，Al₂O₃ 18.0～20.0％，Fe₂O₃0.3～0.5％，TiO₂ 0.1～0.3％，CaO 0.2～0.7％，MgO 0.3～0.8％，K₂O 1.7～2.7％，Na₂O2.8-3.8%. According to the design effect of the whole product and the requirement of a material distribution process, high-strength and high-fluidity powder needs to be prepared. The method is used for testing and screening plastic raw materials, preferably selecting high-strength plastic clay and simultaneously considering good slurry flow property.

In the test process, four kinds of clay with better plasticity on the market are selected for basic physical property detection, and partial physical and chemical properties of the used clay raw materials are shown in table 1.

TABLE 1 Clay physical Properties

The chemical total analysis of the clay raw material is shown in table 2; the XRD mineral composition analysis of the clay raw material is shown in Table 3; XRD patterns of 03 water-washed clay, QX water-washed clay, high-whiteness ball clay and Zhongshan mud are shown in figures 1, 2, 3 and 4.

TABLE 2 Clay chemical composition (%)

TABLE 3 XRD mineral composition analysis of clay-based raw materials

As can be seen from Table 1, the strength of the high-whiteness ball clay sample is 4.3MPa, which is about 5-10% higher than that of the other three plastic clay samples, and the QX water-washed clay has no flow rate, the sizing agent is difficult to peptize, and the brightness of Zhongshan mud is poor.

The clay is added into the formula for testing, and the judgment result is confirmed. The chemical components of the selected sandstone raw materials are shown in the following table 4.

TABLE 4 raw material chemical composition (%)

03 water-washed clay, QX water-washed clay, kaolin and Zhongshan mud are respectively introduced into the formula according to 25 percent, and are recorded as a formula A, B, C, D, and the basic physical properties are detected as shown in Table 5.

Table 5 formulation testing

The test method is as follows:

(1) and test sample preparation: weighing 400g of dry materials, adding 200g of water, adding 2g of sodium tripolyphosphate and 650g of ball stones, carrying out ball milling for 25 minutes in a rapid ball mill, and discharging balls of the ball-milled slurry to pass through a standard sieve with 80 meshes.

(2) And whiteness test: and (3) drying, pulverizing, making a cake, then firing in a kiln (the firing temperature of a temperature measuring ring is 1185 +/-5 ℃), and detecting the whiteness data of the fired sample by using a whiteness meter.

(3) And pH value test: a dropper is used to take a sample of the slurry and drop it onto a pH test paper, and the pH value is measured with reference to a standard pH test paper.

(4) And flow rate testing: after the prepared slurry sample was sufficiently and uniformly stirred, the fluidity thereof was measured using a flow cup, 3 times, and the arithmetic mean thereof was taken as the actual flow rate.

(5) And testing strength: putting the prepared slurry sample into a microwave oven, completely drying the moisture, roughly crushing the dry material, uniformly spraying 8% of water, sieving the powder with a 30-mesh standard sieve for granulation, ageing the powder prepared into granules for 2 hours, preparing small test strips, weighing 35g each time, pressing the test strips by using an HY-YZ electric hydraulic press under the pressure of 15MPa, repeatedly pressing 5 test strips, putting the test strips into an oven, drying the test strips for 3 hours till the test strips are completely dried, and taking the arithmetic mean as the actual strength.

The test data are shown in Table 6.

TABLE 6 basic physical Properties of the formulations

As can be seen from Table 6, formula C uses high whiteness ball clay, and has good flow rate, strength and whiteness, and the chemical components are shown in Table 7.

TABLE 7 formulation chemistry

In order to increase the strength of the base powder, chemical materials can be introduced into the base powder. For example, the chemical materials were added to formulation C and ball milled together to test the physical properties in the same manner as the powder test described above.

The formula C is added with a special effect reinforcing agent (mainly comprising a copolymer organic high polymer material of carboxylic acid and sodium sulfonate), sodium carboxymethyl cellulose (CMC) and a blank reinforcing agent (modified starch) to influence the strength of the dry test strip. The test results are shown in FIG. 5. As can be seen in fig. 5, the dry bar strength of the formulation increased with increasing amounts of additive used. The effect of using the specific enhancer is obviously better than that of other chemical materials.

The effect of formula C on the degummed property of the slurry using the specific enhancer, sodium carboxymethylcellulose, and the green body enhancer, respectively, is shown in fig. 6. As can be seen from fig. 6, the disperging performance of the slurry becomes worse with the increase of the amount of the additive used, and the flow rate increases. When the specific effect reinforcing agent is used in the formula in a proportion of 0.4 percent (wt%), the flow rate of the slurry is acceptable; the flow rate of the sodium carboxymethylcellulose is increased most obviously along with the increase of the addition amount; when the green-body reinforcing agent is added in an amount exceeding 0.2 (wt%), the dispergation property begins to deteriorate.

Therefore, from the aspects of strength and flow rate, 0.3-0.5 (wt%) of special effect reinforcing agent is selected and added into the formula for use.

In some embodiments, the particle size distribution of the base powder is: more than 30 meshes: 5-15%, 30-60 mesh: not less than 75%, 60-80 mesh: less than or equal to 5 percent, and the content of 80 meshes is as follows: less than or equal to 5 percent.

The tests were carried out with the addition of 0.4% by weight of specific effect enhancers in formulation C, compared with the flowability of the base powder in the different particle size classes. According to the test results, the larger the volume weight of the powder, the smaller the particles of 30 mesh or more and 60 mesh or less, and the better the flowability of the powder (50mL, discharge port diameter 3.5mm), and the test data are shown in Table 8.

TABLE 8 comparison of flowability of base powders of different particle size distribution in a flow cup

And (3) after powder spraying granulation of the slurry in a spray tower is carried out and the slurry is put into a powder box, the flowability of the slurry is compared with the flowability of the slurry in the powder box under the condition of exhausting air in an air draft manner at different ageing times. According to the test results, the powder box starts air draft and exhausts, the ageing time is more than 16 hours, the better the flowability of the powder is, and the test conditions are shown in Table 9.

TABLE 9 comparison of flowability under draft and exhaust of powder box for different staling times

Powder box powder sticky powder pairs are shown in fig. 7 and 8. FIG. 7 shows the situation that the powder is adhered to the wall when the powder box exhausts air, and the powder is free of adhering wall and has good fluidity. FIG. 8 shows the situation that the powder is adhered to the wall when the powder box is not used for exhausting air and exhausting air, the powder is seriously adhered to the wall and drips, and the powder is poor in flowability.

Through experimental comparison and analysis, the high-whiteness ball clay is selected as a plasticity raw material of the formula, and the addition amount is 20-30%; the specific reinforcing agent is introduced to enhance the dry strength of the base powder, and the addition amount is 0.3-0.5 (wt%), and the dry test strip strength can be improved by about 17%. Selecting more than 30 meshes: 5-15%, 30-60 mesh: not less than 75%, 60-80 mesh: less than or equal to 5 percent, and the content of 80 meshes is as follows: powder with grain size less than or equal to 5 percent is taken as production parameter. Meets the requirements of the whole product design and the material distribution process, and prepares the high-strength and high-fluidity base powder.

According to the invention, through developing a formula, a clay raw material with high plasticity is selected, a specific effect reinforcing agent is added into the formula, the strength and the fluidity of the powder are enhanced, a proper grain composition is selected, the performance of the basic powder is stabilized, and the requirement of micro cylinder gate blanking on the powder is met.

Subsequently, the prepared toner is conveyed to a distribution apparatus (in the case where the present invention is not specifically described, the distribution apparatus may also be referred to as a digital distribution system). The distributing equipment comprises a hopper for storing toner, a micro cylinder gate for controlling the opening according to the color depth of a pre-designed pattern so as to control the discharging position and the discharging amount of the toner, a distributing belt for containing the toner for discharging, and a feeding belt for conveying the toner to the press forming belt.

The schematic diagram of the digital material distribution system is shown in fig. 9, and the digital material distribution system comprises a hopper 1, a micro cylinder gate 2, a material distribution belt 3 and a feeding belt 4. Specifically, the micro cylinder gate 2 is arranged at the discharge port of the hopper 1, and the opening degree of the micro cylinder gate 2 can be controlled according to the color depth of the surface pattern, so that the toner blanking position and the blanking amount are controlled. The cloth belt 3 is arranged below the micro cylinder gate 2. The feeding belt 4 is arranged at the downstream of the cloth belt 3. The hopper 1 may be provided with 1 or more, and fig. 9 exemplarily shows 6 hoppers (a to f) arranged along the conveying direction of the cloth belt 3, but the present invention is not limited thereto, and the number and arrangement position of the hoppers 1 may be set as needed. In the schematic view shown in fig. 9, the feed belt 4 is located below the distribution belt 3, and the distribution belt 3 is formed in a structure that is disposed substantially in parallel below the hopper 1 and gradually inclines downward at the downstream end in the conveying direction thereof until contacting the feed belt 4.

More specifically, a schematic view of the micro-cylinder gate 2 is shown in fig. 10. The micro cylinder gate 2 includes a shutter 5 for opening and closing the discharge port of the hopper 1, a cylinder 6 connected to the shutter 5, and a gas pipe 7 for supplying gas to the cylinder 6. The cylinder 6 is connected with the gate plate 5 through an expansion link of the cylinder, so that the gate plate 5 can be driven to open and close through the work of the cylinder 6, and the opening degree control of the miniature cylinder gate 2 is realized. In the example shown in fig. 10, the shutter 5 is formed in a substantially L-shaped plate shape, and includes a shutter portion that can open and close the discharge port, and a connecting portion that extends upward from the shutter portion and is connected to the telescopic rod of the cylinder. Although fig. 10 shows only one shutter 5, it should be understood that the shutter 5 may be provided in plurality along the length direction of the discharge port, and each shutter 5 is provided with one cylinder 6 correspondingly, and the opening degree control is realized by air supply control of the air pipe 7. That is, each hopper 1 may be provided with a plurality of micro cylinder gates 2 along the length direction of its discharge port. The air pipe 7 can be connected to a compressed air manifold of the distribution apparatus. The compressed air manifold may be connected to a compressed air supply unit. Valves are provided between the air pipes 7 and the compressed air main pipe, and the amount of air supplied from the compressed air main pipe to each air pipe 7 can be controlled by adjusting the opening of the valves, so that the corresponding operation of each air cylinder 6 is controlled, and the opening and closing of the shutter 5 are realized. The valves may be connected to a control unit, such as a programmable controller or a computer, i.e. the control unit may control the amount of gas in each gas tube 7 by controlling the opening of the valves according to a graphic file (e.g. a pre-designed pattern color shade).

Furthermore, the device also comprises an automatic pressurizing air storage cylinder for stabilizing the air pressure for the air cylinder and the opening degree of the micro air cylinder gate. Fig. 13 is a schematic view of an air reservoir comprising a cylinder and a pressure gauge 8, a compressed air inlet 9 and a compressed air outlet 10 provided on the cylinder. The air storage cylinder is connected between the compressed air supply unit and a compressed air main pipe of the distributing equipment. Specifically, a compressed air inlet 9 of the air storage cylinder is connected with a compressed air supply unit, and a compressed air outlet 10 of the air storage cylinder is connected with a compressed air main pipe of the cloth equipment, so that the air pressure fluctuation of the digital cloth equipment is reduced, and the stability of cloth patterns is ensured.

The device decomposes the picture layer behind the picture according to photoshop, via the tolerance of control unit control trachea 7, and then the switching time of the flashboard 5 of control in miniature cylinder gate 2 controls the toner and is in cloth belt unloading position and unloading volume to make the inside unanimous with surface color of product, reach the effect of whole body.

The cloth flow chart is shown in fig. 11. The toner is conveyed to a hopper, the discharging is controlled through a micro cylinder gate, the stacking of the pigment on a cloth belt is realized, and then the toner is conveyed to a press molding belt through a feeding belt.

The pattern file of the series products is decomposed into a plurality of layers through Photoshop software processing according to the distribution condition of the color system in the pattern, the layers are imported into Auto CAD software and processed into a graphic file capable of controlling the opening of the micro cylinder gate, and the graphic layer A, B, C, D is shown in FIG. 12 as an example.

And (3) according to the material distribution direction, each grid represents the opening degree of a micro cylinder gate, the opening degree of the micro cylinder gate moves from top (row) to bottom (row), in the execution process of each row, a marked place (dark color grid in the figure) represents that the position gate is opened, and no mark represents that the position gate is not opened, and the like, so that the material distribution of the layer is completed. According to the cloth direction between the layers, when the material distributed on the first line of the A layer runs on the cloth belt and reaches the position of the B layer, the first line of the B layer starts to feed, and so on until the C layer and the D layer are obtained, and the layers are stacked through feeding to finish a layout cloth.

The powder is accumulated in a punctiform manner from the blanking of each gate to the cloth belt, certain boundary lines exist among powder points, the patterns can be in a sawtooth shape, and the sawtooth image is reduced by testing the running speeds of the cloth large belt and the feeding belt, so that the surface patterns are transited naturally. In some embodiments, the speed ratio of the distribution belt to the feed belt is 25: 25-25: 33. for example, the speed of the cloth belt is 15-30 Hz, and preferably, the speed of the cloth belt is 25 Hz. For example, the speed of the feeding belt is 27-33 Hz, and preferably, the speed of the feeding belt is 27 Hz. The product test parameters were set to optimize the results of test 3 in view of the product thickness requirements. The test results are shown in table 10:

TABLE 10 comparison of belt run speed results

The digital material distribution system has the following material distribution principle: the digital material distribution system is provided with color powder hopper groups, different colors are placed in corresponding powder hoppers, and the opening time of the gate of the micro cylinder of each color powder hopper is controlled by using the picture processing function of photoshop software according to the texture patterns of the file pictures. According to the difference of the texture and the color of the layout, the optimal opening time of the cylinder gate is 1-5 s. And stacking the various color powders on a cloth belt according to the texture pattern effect of the file picture, thereby obtaining clear granite pattern texture. Because the bottom surface is always consistent in the material distribution process, the patterns are completely coherent, and the patterns on the section are natural and continuous, the complete whole body effect of the formed product can be ensured.

The technological parameters of the all-through cloth material are controlled as follows:

the selection of the air cylinder, the micro air cylinder gates with different specifications and different texture effects of the cloth patterns. The smaller the caliber of the gate of the micro cylinder, the small the point of the cloth, the small the toner flow diffusion surface, the higher the definition of the texture of the layout (the small saw-tooth shape), but the more easily the powder blocks the gate; on the contrary, the clearer the texture of the layout (the more jagged the texture is), but the more smooth the gate blanking. The multiple groups of the micro cylinders are arranged side by side, and each row is more than 60-90 micro cylinders, so that the patterns are ensured to be connected transversely. Preferably, the discharge area controlled by each micro cylinder is (6-25) × (6-25) mm. According to the test result of the influence of different specifications of the micro cylinder on the pattern texture definition, the test 3 is selected as the specification of the test version gate, and the specific result is shown in the table 11.

TABLE 11 micro Cylinder Specification to Pattern texture sharpness test

Secondly, the speed of the cloth belt is selected, the running speeds of the cloth belt are different, the opening time of the gate of the micro cylinder is short, and the instantaneous blanking amount is changed along with the opening time, so that the pattern texture definition is influenced. Considering the production yield and layout effect, the cloth speed of test 3 is selected as a test parameter, and the belt cloth speed affects the test result on the pattern texture definition, which is shown in table 12.

TABLE 12 cloth Belt speed vs. Pattern texture definition test

The material distribution equipment which adopts a belt mode to feed materials to a press for pressing and forming consists of two groups (or more than two groups) of belts, namely a material distribution belt and a material feeding belt. The material distributing belt and the material conveying belt of the traditional material distributing device are on the same horizontal plane, the material is thrown to the material conveying belt in a speed inertia mode of the material distributing belt, and due to the fact that the material throwing and the material conveying belt have a speed difference, the texture patterns distributed by powder materials can generate a large deformation phenomenon. The feeding mode of the digital material distribution system is different from the traditional feeding mode, the material distribution belt and the material feeding belt are arranged in a height mode, the material distribution belt is arranged on the upper portion, the material feeding belt is arranged on the lower portion, powder freely falls onto the material feeding belt from the material distribution belt, and the texture and pattern fidelity is good. By using the feeding mode, the deformation of the cloth patterns in the conveying process can be prevented.

The traditional filling mode is that a feeding belt moves to the front end of a press die cavity, a lower die of the press descends, the feeding belt is filled in a blanking mode, and due to the flowability of powder, the filling flatness is poor, a blank body is easy to have thickness, the size deviation is serious, and shrinkage cracks are formed in the blank body. The invention adopts a new filling mode, namely a press die cavity filling mode, wherein a feeding belt moves to the front end of a press die cavity, a lower die of the press is not moved, after the feeding belt finishes the blanking action, the lower die of the press descends again, and after powder stops flowing, the lower die descends again, so that the filling flatness of the powder is better, the thickness and the size deviation of a blank body are better, and the sintering shrinkage cracking is better than that of the traditional filling mode.

The press can produce a large amount of discarded clouts in the press forming process, and the discarded clout all comprises multiple toner mixture behind the cloth, and traditional cloth equipment can't direct stable recycle, especially when producing the full-through product, often can only retrieve to go into the ball again in the raw materials, and the wasting of resources is amazing, and product cost is high or low. According to the characteristics of a digital material distribution system and granite stones, a direct recycling mode of waste excess materials is found. Reserving 1-2 groups of color hoppers from a multi-group of color powder storage system, collecting excess materials into a large storage device, uniformly mixing, and then sending the mixture to the reserved color powder hoppers to be used as new color powder. The product performance of the product is not influenced, and a large amount of excess materials can be recycled, so that the recycling rate can reach 100 percent.

Because the invention is provided with a large number of micro cylinders, the use amount of compressed air is large in the operation process, and the stability of air pressure is very important for accurately opening and closing the micro cylinder gate, the installation of the air pressure stabilizing device is the key for ensuring the stability of material distribution.

In order to achieve the effect of abundant patterns and colors of natural stone layout, the latest distribution equipment is composed of a plurality of modules and a plurality of devices, pneumatic elements are continuously increased, the requirement on compressed air is higher and higher, and the stability of air pressure is crucial to the distribution effect of the distribution equipment. In order to reduce the large fluctuation of the air pressure of the material distribution equipment, through various experimental schemes, a scheme of adding an automatic pressurizing air storage cylinder device to the material distribution equipment is selected, and through actual use, the pressure stabilizing effect achieves the production expected target. The main work flow and principle are as follows: the compressed gas is firstly stored in an automatic pressurizing gas storage cylinder container newly added in the material distribution equipment, the gas pressure is increased from 6kg to 8kg, and then the pneumatic element of the material distribution equipment is connected. After the automatic pressure air storage cylinder is added, even if the pneumatic elements of the material distribution equipment use air at the same time, the air pressure in the automatic pressure air storage cylinder is instantly reduced to 5kg, and the material distribution effect is basically not influenced. By contrast, when the pneumatic element of the distributing equipment uses air simultaneously before the automatic pressurizing air storage cylinder is not installed, the air pressure is instantly reduced to 3kg from 6kg, and the distributing effect is greatly influenced. FIG. 13 is a schematic view of an air reservoir. Through increasing the automatic pressurization gas storage cylinder, stabilize skip atmospheric pressure to stabilize air pressure for the miniature cylinder, stabilize the gate aperture.

In some embodiments, the product surface decoration effect and antifouling property can be enhanced through spray drying particles.

After the product is formed, a code spraying machine is used for spraying codes on the edge of a green brick, after the green brick is dried, the code spraying machine is used for identifying the code spraying, a graphic file corresponding to the code spraying is printed, the texture details on the surface of the green brick are decorated, a few granite patterns which are brought by the material distributing method are eliminated, and the patterns achieve the effect of natural granite. Some examplesIn the application mode, a layer of dry granular glaze is sprayed, preferably transparent dry granular glaze, so that the surface texture of the glaze is improved, and the antifouling performance is improved. In some embodiments, the chemical composition of the dry particulate glaze may be: loss on ignition of 4.0-4.5%, SiO₂ 48～52％，Al₂O₃ 15～19％，Fe₂O₃ 0.1～0.3％，TiO₂ 0.05～0.2％，CaO 3.0～5.0％，MgO 1.5～3.0％，K₂O 7.0～9.0％，Na₂1.0-3.0% of O. In some embodiments, the specific gravity of the dry particle glaze can be 1.28-1.35, and the application amount of the dry particle glaze is 170-230 g/m². And finally, firing the green brick. In some embodiments, the firing temperature is 1180 to 1200 ℃ and the firing period is 60 to 70 min. A production process flow diagram, as shown in fig. 14.

Through the test and screening of plastic raw materials, high-strength clay is selected, and a specific reinforcing agent is introduced, so that the strength of powder is improved, and the flowability of the powder is increased. The texture that traditional roller distributing device cloth was hard, lifelike degree is poor. The digital material distribution system distributes materials according to file pictures after the layers are decomposed by computer photoshop software, fixed-point, positioning and quantitative material distribution can be achieved, and patterns and textures of produced products are varied.

Through research and development digital cloth equipment, utilize the fine powder that high strength, mobility are good, solve the pattern definition problem, reach unanimous with the surface pattern to obtain the effect that cloth mode realized the full entire body once.

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

1. And (3) ball-milling the blank raw materials according to a formula, sieving to remove iron, preparing slurry, matching colors, spraying powder, and ageing powder to obtain the toner. The fineness of the slurry is 0.7 percent (250 meshes of residue), the flow rate of the slurry is 55s, and the specific gravity of the slurry is 1.69. The moisture of the toner was 7.5%.

2. The prepared standard toner is stored in a toner box, the standard toner with different colors is conveyed into corresponding hoppers in digital distributing equipment by a conveying belt, a corresponding graphic file is transferred from a computer to a control unit on the digital distributing equipment, the opening of a micro cylinder gate 2 is controlled by the control unit according to the preset pattern texture of the file for distributing, and the standard toner is pressed into a blank body to form the effect of the whole granite. Forming frequency: and 5. fermenting for 3.2-3.5 times/min. Forming thickness: 12.2 + -0.2 mm. Molding pressure: 310 bar. The size of the die is as follows: 890X 890 mm.

3. And (5) stamping a bar code on the blank body. Because the pattern corresponds a plurality of layers during product production, in order to prevent the layer confusion when the detail defect is decorated in the later stage inkjet, carry out the code spraying at the adobe edge with ink jet numbering machine.

4. And drying the green body by using a drying kiln. The drying period of the green brick is about 80min, and the water content of the dried green brick is less than or equal to 0.5 percent.

5. And carrying out ink jet on the dried blank. And the ink jet machine identifies the code spraying, prints a corresponding graphic file and decorates the detail of the surface texture of the green brick.

6. Spraying dry granular glaze with the specific gravity of 1.31; the application amount of the dry grain glaze is 200g/m²。

7. And firing the green bricks after the dried granules are sprayed. The sintering temperature is 1190 ℃, and the sintering period is 65 min. The firing profile is shown in FIG. 15 below.

The product effect diagrams are shown in fig. 16 and 17. As can be seen from FIGS. 16-17, the ceramic tiles of the present invention have a full body granite effect.

Claims

1. The distribution equipment for the whole-body granite ceramic tile is characterized by comprising a hopper for storing toner, a micro cylinder gate for controlling the opening according to the color depth of a surface pattern so as to control the blanking position and the blanking amount of the toner, a distribution belt for containing the toner for blanking, and a feeding belt for conveying the toner to a pressing type belt;

the miniature cylinder gate is arranged at the discharge port of the hopper and comprises a gate plate capable of opening and closing the discharge port of the hopper, a cylinder connected with the gate plate and an air pipe for supplying air to the cylinder; the cylinder is connected with the gate plate through a telescopic rod of the cylinder, so that the opening and closing actions of the gate plate can be driven through the work of the cylinder, and the opening control of the miniature cylinder gate is realized;

the cloth belt and the feeding belt are arranged in a high-low mode, wherein the cloth belt is arranged above the feeding belt, and the feeding belt is arranged below the feeding belt; specifically, the feeding belt is positioned below the distribution belt, and the distribution belt is formed into a structure which is arranged below the hopper in parallel and gradually inclines downwards at the downstream end of the conveying direction until the distribution belt is contacted with the feeding belt;

the material distribution equipment also comprises an automatic pressurizing air storage cylinder for stabilizing the air pressure for the air cylinder and the opening degree of the gate; the air storage cylinder comprises a cylinder body, and a pressure gauge, a compressed air inlet and a compressed air outlet which are arranged on the cylinder body; the compressed air inlet of the air storage cylinder is connected with the compressed air supply unit, the compressed air outlet of the air storage cylinder is connected with the compressed air main pipe of the material distribution equipment, and therefore pressure fluctuation of the material distribution equipment is reduced, and stability of the material distribution patterns is guaranteed.

2. The material distribution equipment as claimed in claim 1, wherein the micro cylinder gate comprises a plurality of groups of cylinders arranged side by side, and each row comprises more than 60-90 cylinders.

3. The material distribution equipment according to claim 2, wherein the discharge area controlled by each cylinder is (6-25) × (6-25) mm.

4. The material distribution method for preparing the through granite ceramic tile by using the material distribution device as claimed in any one of claims 1 to 3, characterized in that the color and the blanking position of the toner are selected according to a graphic file for controlling the micro-cylinder gate, and the opening time of the micro-cylinder gate is controlled according to the color shade change of the texture of the graphic file, so that the toner is stacked and distributed on the material distribution belt, and the through granite pattern texture effect with the consistent color, texture surface and inside is obtained.

5. The material distribution method according to claim 4, wherein the speed ratio of the material distribution belt to the feeding belt is 25: 25-25: 33.

6. the material distributing method according to claim 5, wherein the speed of the material distributing belt is 15-30 Hz of the motor frequency of the belt, and the speed of the material feeding belt is 27-33 Hz.

7. The material distributing method according to claim 4, wherein the thickness of the material is 5-30 mm.

8. The preparation method of the whole granite ceramic tile is characterized by comprising the following steps: (1) distributing toner using the distributing method of any one of claims 4 to 7; (2) pressing, molding and sintering to obtain the whole granite ceramic tile.

9. The production method according to claim 8, wherein the toner includes a base powder and a colorant; the base powder comprises 20-30% of high-whiteness ball soil by mass.

10. The method of claim 9, wherein the chemical composition of the base powder comprises: by mass percentage, the loss on ignition is 3.5-5.5%, and SiO is₂66.0～70.0%，Al₂O₃18.0～20.0%，Fe₂O₃0.3～0.5%，TiO₂0.1～0.3%，CaO 0.2～0.7%，MgO 0.3～0.8%，K₂O 1.7～2.7%，Na₂O 2.8～3.8%。

11. The method according to claim 9, wherein the base powder further comprises a reinforcing agent in an amount of 0.3 to 0.5%.

12. The method according to claim 9, characterized in that the granulometric composition of the base powder is: more than 30 meshes: 5-15%, 30-60 mesh: not less than 75%, 60-80 mesh: less than or equal to 5 percent, and the content of 80 meshes is as follows: less than or equal to 5 percent.