CN111470856B - Thin ceramic rock plate and preparation method thereof - Google Patents
Thin ceramic rock plate and preparation method thereof Download PDFInfo
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- CN111470856B CN111470856B CN202010273317.8A CN202010273317A CN111470856B CN 111470856 B CN111470856 B CN 111470856B CN 202010273317 A CN202010273317 A CN 202010273317A CN 111470856 B CN111470856 B CN 111470856B
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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
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/16—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay
- C04B35/18—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silicates other than clay rich in aluminium oxide
- C04B35/19—Alkali metal aluminosilicates, e.g. spodumene
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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
- C03C8/02—Frit compositions, i.e. in a powdered or comminuted form
- C03C8/04—Frit compositions, i.e. in a powdered or comminuted form containing zinc
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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
- 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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- 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
- C03C8/22—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions containing two or more distinct frits having different compositions
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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
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
- C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
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- C04B2235/30—Constituents and secondary phases not being of a fibrous nature
- C04B2235/32—Metal oxides, mixed metal oxides, or oxide-forming salts thereof, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/3217—Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
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- C04B2235/34—Non-metal oxides, non-metal mixed oxides, or salts thereof that form the non-metal oxides upon heating, e.g. carbonates, nitrates, (oxy)hydroxides, chlorides
- C04B2235/349—Clays, e.g. bentonites, smectites such as montmorillonite, vermiculites or kaolines, e.g. illite, talc or sepiolite
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- C04B2235/44—Metal salt constituents or additives chosen for the nature of the anions, e.g. hydrides or acetylacetonate
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Abstract
The invention relates to a preparation method of a thin ceramic rock plate. The thin ceramic rock plate blank consists of the following components in percentage by weight: 8-12% of ball clay; 17-20% of washing kaolin; 4-7% of high white kaolin; 18-20% of water-milled ultra-white potassium stone powder; 38-40% of terrazzo albite by water grinding; 4-5% of high-whiteness alumina powder; 0-2% of ultra-white zirconium silicate; 3.5 to 7.5 percent of calcined talc; 1-1.5% of a debonder; 2-2.5% of a polymerization solution. The preparation method of the thin ceramic rock plate comprises the following steps: blank material mixing → blank processing → spray drying powder making → dry pressing molding → blank brushing and ash removing → roller priming glaze printing → pattern decoration → pattern protective layer decoration → firing → polishing and edge grinding.
Description
Technical Field
The invention belongs to the technical field of ceramic sheets, and particularly relates to a thin ceramic rock plate and a preparation method thereof.
Background
The ceramic thin plate has a thickness of less than 6mm and an area of more than 1.62m2The ceramic tile. Compared with similar products, the unit area of the ceramic sheet is reduced by more than one time compared with the conventional building ceramic material, so that more than 60 percent of raw material resources can be saved, and the comprehensive energy consumption can be reduced by more than 50 percent, and the low-carbon targets of material saving and energy saving are well realized no matter the consumption of the raw materials or the energy consumption in the production process; meanwhile, the ceramic sheets are light, so that the logistics transportation cost is saved, and the load of a building is reduced. However, because the ceramic thin plate is thin and has a large area, the problems of low strength, poor toughness and the like of green bodies and finished products are easy to occur in the production process. Therefore, the deformation and the breakage of the thin plate are easily caused no matter the green body is prepared, transported or sintered.
In actual production, the reasonability of a blank formula and a product surface decoration process technology plays a very key role in adapting the ceramic large plate to actual production, and the phenomenon that the strength of the ceramic large plate blank is too low due to unreasonable design in any link can occur, so that more cracks and broken bricks are generated in the production process. In the prior art, CN201310453497.8 and CN201510038830 both disclose methods for manufacturing ceramic sheets, both the two ceramic sheets are produced by a process of biscuit firing and glaze firing for two times, and CN201911058826.2 discloses a large-sized ceramic rock plate and a production process thereof, and provides a large-sized ceramic rock plate and a production process thereof.
Disclosure of Invention
The invention aims to solve the problems that a blank body of a thin ceramic rock plate with the thickness of less than 6mm (particularly the thickness of 3mm) is easy to absorb excessive water or nonuniform water after water glaze decoration in the production process, the blank body is easy to crack when dried, the strength of the blank body is low, the toughness of a finished product is poor, and a thin plate is easy to deform and damage in the process of preparing, transferring and sintering the blank body, and provide a preparation method of the thin ceramic rock plate, wherein the blank body is free of drying and biscuit firing and does not contact water in the surface decoration in the production process, so that the phenomenon of drying and cracking caused by excessive water absorption or nonuniform water absorption in the product is avoided.
The technical scheme of the invention is that the thin ceramic rock plate is characterized in that a blank comprises the following components in percentage by weight:
wherein: the aluminum content of ball clay and washing kaolin is more than 35 percent, and the iron content is less than 0.3 percent; the specific surface area of the high white kaolin is 20-30 m2(g), particle size distribution D9018.5-19.3 μm, whiteness >82 °, LAB value is: l: 94.6-96.5, A: 0.52-1.2, B: 5.3 to 6.5; the iron content of the water-milled ultra-white potassium stone powder and the water-milled albite is less than 0.3 percent; the high-whiteness alumina powder has the aluminum content of 99.33 percent, the iron content of 0.03 percent and the particle size distribution of D9010.2-11.5 mu m; the debonder is one or more of sodium tripolyphosphate, sodium hexametaphosphate, sodium humate, sodium polyacrylate, polycarboxylate substances of sodium polyacrylate, or specific ceramic debonder; the polymerization liquid is a mixture of water glass, modified lignin, polyvinyl alcohol glue silk solution, polyacrylate, carboxyl cellulose and acrylate copolymer, phosphate and the like.
Preferably, the method comprises the following steps: the thin ceramic rock slab comprises the following chemical components in percentage by weight:
the chemical components of the high-white kaolin comprise the following components in percentage by weight:
preferably, the method comprises the following steps: the ground glaze of the thin ceramic rock plate consists of the following components in percentage by weight:
The roller for printing the ground glaze is a silica gel foaming rubber roller, and the Shore hardness of a surface rubber sheet is 8-10 degrees; the roller adopts one carving method of laser 04 double carving, GS and Mask, the gray level of the design of the carving pattern is 80-100%, the depth of the carving hole is 400-800 mu m, and the aperture size is 0.4-0.5 mm.
Preferably, the method comprises the following steps: the zirconium white frit consists of the following components in percentage by weight:
the invention also provides a preparation method of the thin ceramic rock plate, which is characterized in that the thin ceramic rock plate adopts a green body drying-free and biscuit firing production process, and comprises the following steps:
the method comprises the following steps of: comprises ball clay, water-washed kaolin, high-white kaolin, water-milled ultra-white potassium stone powder, water-milled albite, high-white alumina powder, ultra-white zirconium silicate, calcined talc, dispergator and polymerization solution;
secondly, processing the blank: batching and ball-throwing are carried out according to the blank formula, and multistage continuous ball-milling equipment is adopted for processing; the processing parameters of the blank slurry are as follows: 1.5-1.8% of screen residue with the fineness of 325 meshes, 31-33% of water, 1.71-1.75% of specific gravity, and the flow rate is 90-110 s, and the obtained slurry is placed into a slurry tank and then is aged for more than 24 h;
thirdly, spray drying for milling: powder control parameters: 3-8 wt% of 30-mesh particle composition, 20-25 wt% of 40-mesh particle composition, 30-35 wt% of 50-mesh particle composition, 15-20 wt% of 60-mesh particle composition, 6-11 wt% of 80-mesh particle composition, less than or equal to 3 wt% of 120-mesh particle composition, 1.0-1.1 g/ml volume weight, 5.5-6.5% of water content, the temperature of the obtained powder taken out of a tower is less than 80 ℃, and the obtained powder is conveyed to a storage bin for ageing for more than 48 hours;
Fourth, dry pressing forming: the belt type die-frame-free press or die-frame-type press is adopted for pressing and forming, and the pressing pressure is 360-420 Kg/cm2And blank specification: the length is 1.2-3.6 m, the width is 0.6-1.6 m, and the thickness is less than 6 mm;
carrying out dust removal on the brush blank: treating impurities on the surface of the thin ceramic rock plate blank by adopting a brush and a bag-type dust collector;
sixthly, printing a base glaze slip by a roller: adopting 1-4 rollers on a four-channel roller printing machine to perform roller printing on the surface of a clean thin ceramic rock slab blank, wherein the base glaze slurry is selected to be an opaque type, a semi-opaque type or a transparent type according to the depth and the tone of the product color; the ground glaze slurry is prepared by processing 30-50% of ground glaze material and 50-70% of solvent through a rapid ball milling dispersion machine, and a screen with the fineness of 325 meshes passes through the ground glaze slurry;
hobby pattern decoration: adopting 8-12 channel ink-jet equipment to decorate the color and the concave-convex effect of the thin ceramic rock plate product;
and pattern protection layer decoration;
the self-supporting burn: directly conveying the thin ceramic rock plate blank decorated by the glaze line to a firing kiln for firing a finished product, wherein the firing maximum temperature is 1170-1195 ℃, the high-fire heat preservation time is 7-10 minutes, and the firing time is 130-180 minutes.
Preferably, the method comprises the following steps: the method also comprises the following steps: and (3) post-procedure processing:
1) According to the glaze texture effect of the product, glaze polishing or four-edge trimming and edging treatment is carried out on the thin ceramic rock plate which is fired and taken out of the kiln;
2) and (3) tightly bonding and fixing the reticular film on the back surface of the bottom blank of the thin ceramic rock plate by a fixed film coating method after the polishing and edging treatment.
Preferably, the method comprises the following steps: step 2) the fixation coating film layer method further includes:
2.1) enabling the back of a bottom blank of the thin ceramic rock plate to face upwards by using a brick turning machine;
2.2) uniformly coating the bonding glue on the bottom surface of the ceramic thin plate by using a hairbrush, wherein the thickness of the coating of the bonding glue is 0.5-0.9 mm; wherein the glue is one or more of unsaturated polyester resin, two-component modified epoxy resin glue, two-component high molecular polymer emulsion and inorganic material-organic fiber composite material;
2.3) attaching a reticular film on the bottom surface of the ceramic thin plate; wherein the mesh film is 60 to 100g/m2The thickness of the glass fiber net is 0.7-1 mm;
2.4) fixing the reticular film by a roller press to ensure that the reticular film is tightly bonded with the green body layer, and the reticular film is flat and does not wrinkle;
2.5) using infrared natural gas dryer equipment to quickly solidify the glue, and firmly fixing the film coating layer at the bottom of the blank layer; wherein the infrared natural gas dryer is set at a drying temperature of 300 ℃ and drying time of 3-5 minutes.
Preferably, the method comprises the following steps: the pattern protection layer decoration further includes: selecting one of the materials according to the design requirement of the texture of the glaze surface of the product;
8.1) the working procedure of roller printing matt transparent glaze slip with matt glaze texture: printing matt transparent protective glaze slip on the glaze surface of the thin ceramic rock plate decorated by the ink-jet patterns by adopting 1-4 rollers on a four-channel roller printing machine; the matte transparent protective glaze slurry is prepared by processing 30-50% of matte transparent protective glaze powder and 50-70% of solvent through a rapid ball milling dispersion machine, and a screen with the fineness of 325 meshes is full-through;
8.2) dry granulation procedure is selected for the texture of the bright glaze:
8.2.1) adopting 1-4 rollers on a four-channel roller printing machine to perform roller printing on the glaze surface of the thin ceramic rock plate decorated by the ink-jet patterns and fixing a glue solvent;
8.2.2) adopting a dry particle scattering machine to distribute dry particles on the glaze surface of the thin ceramic rock plate with a fixed glue solvent, wherein the dry particle amount is 650-1000 g/m2；
8.2.3) spraying the fixing glue bonding wetting solvent on the dried grain surface of the thin ceramic rock plate cloth by a spray gun, wherein the spraying amount is 60-100 g/m2。
Preferably, the method comprises the following steps: the matt transparent glaze powder material in the step 8.1) comprises the following components in percentage by weight:
The solvent consists of the following components in percentage by weight:
| 20-50% of glycerol | 45-79% of ethylene glycol | 1-5% of water-retaining solution |
The roller for printing the matt transparent glaze is a silica gel foaming adhesive roller, and the Shore hardness of a surface adhesive sheet is 8-10 degrees; the roller adopts a laser 03 or laser 04 double-engraving method, namely, the laser engraves in the same hole for two times continuously, the design gray level of the engraved pattern is 80-100%, the depth of the engraved hole is 300-500 mu m, and the aperture size is 0.3-0.4 mm.
Preferably, the method comprises the following steps: the frit A comprises the following chemical components in percentage by weight:
the frit B comprises the following chemical components in percentage by weight:
compared with the prior art, the invention has the beneficial effects that:
the method has the advantages that the drying and biscuiting-free process is adopted for the green body, the surface decoration is not contacted with water in the whole production process, the phenomenon of drying and cracking of the product caused by too large water absorption or uneven water absorption is avoided, and meanwhile, the energy consumption is reduced.
The water-milled ultra-white potash powder and the water-milled albite are selected in the blank body formula, so that the particle size is relatively uniform, and the particle size difference with pug is smaller; in addition, microcracks are generated in the grinding process of the water grinding materials, secondary ball milling processing is easy after the water grinding materials and other materials are added into a continuous ball mill, the ball milling processing time is shortened by over 30 percent, and the power consumption is greatly reduced. The invention adopts a water milling mode, can improve the quality of the sand and stone materials with common or poor quality, achieves the aim of producing high-quality thin ceramic rock plates and reduces the delicate selectivity to natural raw materials.
The polymerization solution selected by the invention can increase the strength of the green body, ensure that the green brick is not easy to crack after being decorated, and simultaneously contains the adsorption groups, so that a plurality of fine green brick slurry particles can be adsorbed and agglomerated, the green body powder is favorably formed, the solid degree of the green body powder particles is enhanced, the surface burrs are reduced, and the range of size shrinkage and deformation of the green body is reduced.
Detailed Description
The invention will be further described in detail with reference to the following examples:
the thin ceramic rock plate blank consists of the following components in percentage by weight:
wherein: 39% of aluminum content of ball clay, 0.1% of iron content, 41% of aluminum content of washing kaolin and 0.05% of iron content; high white kaolin specific surface area 28m2(iv)/g, particle size distribution D9019.2 μm, whiteness 85 °, LAB value: l: 94.8, A: 1.1, B: 5.6; the iron content of the water-milled ultrawhite potash stone powder is 0.1 percent, and the iron content of the water-milled albite is 0.08 percent; the high-whiteness alumina powder has the aluminum content of 99.33 percent, the iron content of 0.03 percent and the particle size distribution of D9010.8 mu m; the debonder is a mixture of sodium tripolyphosphate, sodium hexametaphosphate, sodium humate and sodium polyacrylate; the polymerization liquid is a mixture of modified lignin, polyvinyl alcohol collodion silk solution, carboxyl cellulose and acrylate copolymer.
In the embodiment, the thin ceramic rock slab comprises the following chemical components in percentage by weight:
the chemical components of the high-white kaolin comprise the following components in percentage by weight:
the ground glaze of the thin ceramic rock plate consists of the following components in percentage by weight:
the roller for printing the ground glaze is a silica gel foaming rubber roller, and the Shore hardness of a surface rubber sheet is 8 degrees; the roller adopts a laser GS carving method, the designed gray level of a carving pattern is 80-100%, the depth of a carving hole is 500-600 mu m, and the aperture size is 0.4-0.45 mm.
In this embodiment, the zirconium white frit is composed of, by weight:
the preparation method of the thin ceramic rock plate adopts a production process of drying-free and biscuit firing of a blank body, and the main process flow is as follows: blank material mixing → blank processing → spray drying powder making → dry pressing to form the blank → blank brushing ash removal → roller base glaze slurry printing → pattern decoration → pattern protection layer decoration → firing, comprising the following steps:
the method comprises the following steps of: comprises ball clay, water-washed kaolin, high-white kaolin, water-milled ultra-white potassium stone powder, water-milled albite, high-white alumina powder, ultra-white zirconium silicate, calcined talc, dispergator and polymerization solution;
secondly, processing the blank: batching and ball-throwing are carried out according to the blank formula, and multistage continuous ball-milling equipment is adopted for processing; the processing parameters of the blank slurry are as follows: 1.5-1.7% of screen residue with the fineness of 325 meshes, 31-32% of water, 1.71-1.73% of specific gravity and 95-100 s of flow rate, and aging the obtained slurry for more than 24h after the slurry is placed in a slurry tank;
Thirdly, spray drying for milling: powder control parameters: 4-5 wt% of particle composition with a particle size of 30 meshes, 20-23 wt% of 40 meshes, 32-35 wt% of 50 meshes, 15-18 wt% of 60 meshes, 8-10 wt% of 80 meshes, less than or equal to 2 wt% of 120 meshes, 1.0-1.1 g/ml in volume weight, 5.8-6.2% in water content, and the temperature of leaving a tower is less than 70-72 ℃, and the obtained powder is conveyed to a storage bin for ageing for more than 48 hours;
fourthly, dry pressing forming: the pressing forming is carried out by adopting a belt type mould-free frame press, and the pressing pressure is 400Kg/cm2And blank specification: the length is 3.2m, the width is 1.6m, and the thickness is 4.5 mm;
carrying out dust removal on the brush blank: treating impurities on the surface of the thin ceramic rock plate blank by adopting a brush and a bag-type dust collector;
sixthly, printing a base glaze slip by a roller: adopting two rollers 1# and 4# on a four-channel roller printing machine to perform roller printing of the ground glaze slurry on the surface of a clean thin ceramic rock slab blank, wherein the ground glaze slurry is selected to be of an opaque type, a semi-opaque type or a transparent type according to the depth and the tone of the color of a product; the ground glaze slurry is formed by processing 30% of ground glaze material and 70% of solvent through a rapid ball milling dispersion machine, and a screen with the fineness of 325 meshes passes through the ground glaze slurry;
hobby pattern decoration: adopting 8-channel ink-jet equipment to decorate the color and the concave-convex effect of the thin ceramic rock plate product;
decorating with a pattern protection layer: according to the texture design requirement of the glaze surface of the product, the following materials are selected alternatively:
8.1) the matte glaze texture selects the roller printing matte transparent glaze slip process: performing roller printing of matte transparent protective glaze slurry on the glaze surface of the thin ceramic rock plate decorated by the ink-jet patterns by adopting a No. 1 roller on a four-channel roller printing machine; the matte transparent protective glaze slip is formed by processing 40 percent of matte transparent protective glaze powder and 60 percent of solvent through a rapid ball milling dispersion machine, and a screen with the fineness of 325 meshes passes through the protective glaze slip;
the matt transparent glaze powder consists of the following components in percentage by weight:
the solvent consists of the following components in percentage by weight:
| 25% of glycerin | 72 percent of ethylene glycol | The water retention solution is 3% |
The roller for printing the matt transparent glaze is a silica gel foaming adhesive roller, and the Shore hardness of a surface adhesive sheet is 8-10 degrees; the roller adopts a laser 03 double-engraving method, the designed gray level of the engraved pattern is 80-100%, the depth of the engraved hole is 400-500 mu m, and the aperture size is 0.3-0.4 mm.
In this embodiment, the frit a comprises the following chemical components in percentage by weight:
the frit B comprises the following chemical components in percentage by weight:
8.2) dry granulation procedure is selected for the texture of the bright glaze:
8.2.1) adopting a No. 1 roller on a four-channel roller printing machine to perform roller printing on the glaze surface of the thin ceramic rock plate decorated by the ink-jet patterns and fixing a glue solvent;
8.2.2) adopting a dry particle scattering machine to distribute dry particles on the glaze surface of the thin ceramic rock plate with a fixed glue solvent, wherein the dry particle amount is 750-780 g/m2；
8.2.3) spraying the fixing glue bonding wetting solvent on the dried grain surface of the thin ceramic rock plate cloth by a spray gun, wherein the spraying amount is 80-85 g/m2；
The self-supporting burn: directly conveying the thin ceramic rock plate blank decorated by the glaze line to a firing kiln for firing a finished product, wherein the firing maximum temperature is 1175 ℃, the high-fire heat preservation time is 8 minutes, and the firing time is 135 minutes;
the method has the following advantages: and (3) post-procedure processing:
10.1) performing glaze polishing or four-edge trimming and edging treatment on the fired and drawn thin ceramic rock plate according to the glaze texture effect of the product;
10.2) the product after polishing and edging is tightly bonded and fixed on the back of the bottom blank of the thin ceramic rock plate by a fixed film coating method.
The fixation coating layer method further includes:
10.2.1) enabling the back of the bottom blank of the thin ceramic rock plate to face upwards by using a brick turning machine;
10.2.2) uniformly coating bonding glue on the bottom surface of the ceramic thin plate by a brush, wherein the thickness of the coated bonding glue is 0.6 mm; wherein the glue is a mixed solution of unsaturated polyester resin and two-component modified epoxy resin glue;
10.2.3) attaching a net film to the bottom surface of the ceramic thin plate; wherein the reticular film is 65g/m 2The glass fiber net of (2), the thickness of which is 0.7 mm;
10.2.4) fixing the net-shaped film with a roller press to make it closely adhere to the blank layer, and the net-shaped film is flat and has no wrinkles;
10.2.5) using infrared natural gas dryer to make the glue solidify quickly, fixing the film coating layer on the bottom of the blank layer; wherein the infrared natural gas dryer is set with a drying temperature of 300 ℃ and a drying time of 3 minutes.
The above-mentioned embodiments are only preferred embodiments of the present invention, and all equivalent changes and modifications made within the scope of the claims of the present invention should be covered by the claims of the present invention.
Claims (9)
1. The thin ceramic rock plate is characterized in that the thin ceramic rock plate blank consists of the following components in percentage by weight:
8-12% of ball clay, 17-20% of washing kaolin, 4-7% of high-white kaolin, 18-20% of water-milled ultra-white potassium stone powder, 38-40% of water-milled albite, 4-5% of high-white alumina powder, 0-2% of ultra-white zirconium silicate, 3.5-7.5% of calcined talc, 1-1.5% of dispergator and 2-2.5% of polymerization liquid;
the thin ceramic rock slab comprises the following chemical components in percentage by weight:
SiO262.5～63.5%、Al2O323～25%、Fe2O30～0.28%、CaO 0～0.11%、MgO1.3～2.5%、K2O1～1.5%、Na24 to 5 percent of O, and 4.6 to 4.9 percent of O;
wherein: the aluminum content of ball clay and washing kaolin is more than 35 percent, and the iron content is less than 0.3 percent; the specific surface area of the high white kaolin is 20-30 m 2Per g, granuleThe diameter distribution D9018.5-19.3 mu m, the whiteness is more than 82 degrees, and the LAB value is as follows: l: 94.6-96.5, A: 0.52 to 1.2, B: 5.3 to 6.5; the iron content of the water-milled ultra-white potassium stone powder and the water-milled albite is less than 0.3 percent; the high-whiteness alumina powder has the aluminum content of 99.33 percent, the iron content of 0.03 percent and the particle size distribution of D9010.2-11.5 mu m; the debonder is one or more of sodium tripolyphosphate, sodium hexametaphosphate, sodium humate, sodium polyacrylate or polycarboxylate of sodium polyacrylate; the polymerization liquid is a mixture of water glass, modified lignin, polyvinyl alcohol glue silk solution, polyacrylate, carboxyl cellulose and acrylate copolymer and phosphate;
the preparation method of the thin ceramic rock plate adopts a production process of drying-free and biscuit firing of a blank body, and comprises the following steps:
the method comprises the following steps of: comprises ball clay, water-washed kaolin, high-white kaolin, water-milled ultra-white potassium stone powder, water-milled albite, high-white alumina powder, ultra-white zirconium silicate, calcined talc, dispergator and polymerization solution;
secondly, processing the blank: batching and ball-throwing are carried out according to the blank formula, and multistage continuous ball-milling equipment is adopted for processing; the processing parameters of the blank slurry are as follows: 1.5-1.8% of screen residue with the fineness of 325 meshes, 31-33% of water, 1.71-1.75% of specific gravity, and the flow rate is 90-110 s, and the obtained slurry is placed into a slurry tank and then is aged for more than 24 h;
Thirdly, spray drying for milling: powder control parameters: 3-8 wt% of 30-mesh particle composition, 20-25 wt% of 40-mesh particle composition, 30-35 wt% of 50-mesh particle composition, 15-20 wt% of 60-mesh particle composition, 6-11 wt% of 80-mesh particle composition, less than or equal to 3 wt% of 120-mesh particle composition, 1.0-1.1 g/ml volume weight, 5.5-6.5% of water content, the temperature of the obtained powder taken out of a tower is less than 80 ℃, and the obtained powder is conveyed to a storage bin for ageing for more than 48 hours;
fourthly, dry pressing forming: the pressing forming is carried out by adopting a belt type mould-frame-free press or a mould-frame-type press, and the pressing pressure is 360-420 kg/cm2And blank specification: the length is 1.2-3.6 m, the width is 0.6-1.6 m, and the thickness is less than 6 mm;
carrying out dust removal on the brush blank: treating impurities on the surface of the thin ceramic rock plate blank by adopting a brush and a bag-type dust collector;
sixthly, printing a base glaze slip by a roller: adopting 1-4 rollers on a four-channel roller printing machine to perform roller printing on the surface of a clean thin ceramic rock slab blank, wherein the base glaze slurry is selected to be an opaque type, a semi-opaque type or a transparent type according to the depth and the tone of the product color; the ground glaze slurry is prepared by processing 30-50% of ground glaze material and 50-70% of solvent through a rapid ball milling dispersion machine, and a screen with the fineness of 325 meshes passes through the ground glaze slurry;
hobby pattern decoration: adopting 8-12 channel ink-jet equipment to decorate the color and the concave-convex effect of the thin ceramic rock plate product;
And pattern protection layer decoration;
the self-body burns: directly conveying the thin ceramic rock plate blank decorated by the glaze line to a firing kiln for firing a finished product, wherein the firing maximum temperature is 1170-1195 ℃, the high-fire heat preservation time is 7-10 minutes, and the firing time is 130-180 minutes.
2. The thin ceramic rock plate of claim 1,
the chemical components of the high-white kaolin comprise the following components in percentage by weight:
SiO250.5～52.6%、Al2O332.5～35%、Fe2O30～0.7%、TiO20～0.08% 、CaO+MgO 0.15～0.26%、K2O+Na21.3 to 1.6% of O, and 10.5 to 12.6% of the total amount of O.
3. The thin ceramic rock plate of claim 1, wherein the ground glaze of the thin ceramic rock plate consists of, in weight percent:
1-4% of sintered zinc oxide, 0-20% of zirconia, 0-15% of zirconium white frit, 40-50% of potassium feldspar, 5-9% of albite, 10-13% of high-white kaolin, 3-5% of sintered talc and 10-15% of superfine quartz;
the roller for printing the ground glaze is a silica gel foaming rubber roller, and the Shore hardness of a surface rubber sheet is 8-10 degrees; the roller adopts one of laser 04 double-carving, GS or Mask carving methods, the gray level of the design of the carving pattern is 80-100%, the depth of the carving hole is 400-800 mu m, and the aperture size is 0.4-0.5 mm.
4. The thin ceramic rock plate of claim 3, wherein the zirconium white frit consists of, in weight percent:
SiO244～45%、Al2O318～19%、Fe2O30.10～0.15%、CaO4.8～6.0%、MgO 1～2.1%、K2O2.5～3.5%、Na2O3.3～4.2%、B2O33.0～4.0%、ZnO0.5～1%、BaO3.5～4.5%、ZrO211～13%。
5. The thin ceramic rock plate of claim 4, further comprising the steps of: and (3) post-procedure processing:
1) according to the glaze texture effect of the product, performing glaze polishing or four-edge trimming and edging treatment on the fired and drawn thin ceramic rock plate;
2) and (3) tightly bonding and fixing the reticular film on the back surface of the bottom blank of the thin ceramic rock plate by a fixed film coating method after the polishing and edging treatment.
6. The thin ceramic rock plate of claim 5, wherein the fixation coating layer method of step 2) further comprises:
2.1) enabling the back of a bottom blank of the thin ceramic rock plate to face upwards by using a brick turning machine;
2.2) uniformly coating the bonding glue on the bottom surface of the ceramic thin plate by using a hairbrush, wherein the thickness of the coating of the bonding glue is 0.5-0.9 mm; wherein the glue is one or more of unsaturated polyester resin, two-component modified epoxy resin glue, two-component high molecular polymer emulsion and inorganic material-organic fiber composite material;
2.3) attaching a reticular film on the bottom surface of the ceramic thin plate; wherein the mesh film is 60 to 100g/m2The thickness of the glass fiber net is 0.7-1 mm;
2.4) fixing the reticular film by a roller press to ensure that the reticular film is tightly bonded with the green body layer, and the reticular film is flat and does not wrinkle;
2.5) using infrared natural gas dryer equipment to quickly solidify the glue, and firmly fixing the film coating layer at the bottom of the blank layer; wherein the infrared natural gas dryer is set at a drying temperature of 300 ℃ and drying time of 3-5 minutes.
7. The thin ceramic rock panel of claim 4, wherein the step of decorating the pattern protection layer further comprises: selecting one of the materials according to the design requirement of the texture of the glaze surface of the product;
8.1) the working procedure of roller printing matt transparent glaze slip with matt glaze texture: printing matt transparent protective glaze slip on the glaze surface of the thin ceramic rock plate decorated by the ink-jet patterns by adopting 1-4 rollers on a four-channel roller printing machine; the matte transparent protective glaze slurry is prepared by processing 30-50% of matte transparent protective glaze powder and 50-70% of solvent through a rapid ball milling dispersion machine, and a screen with the fineness of 325 meshes is full-through;
8.2) dry granulation procedure is selected for the texture of the bright glaze:
8.2.1) adopting 1-4 rollers on a four-channel roller printing machine to perform roller printing on the glaze surface of the thin ceramic rock plate decorated by the ink-jet patterns and fixing a glue solvent;
8.2.2) adopting a dry particle scattering machine to distribute dry particles on the glaze surface of the thin ceramic rock plate with a fixed glue solvent, wherein the dry particle amount is 650-1000 g/m2；
8.2.3) spraying the fixing glue bonding wetting solvent on the dried grain surface of the thin ceramic rock plate cloth by a spray gun, wherein the spraying amount is 60-100 g/m2。
8. The thin ceramic rock plate of claim 7, wherein the matte transparent protective glaze powder of step 8.1) consists of the following weight percentages:
15-20% of albite, 35-43% of frit A, 15-20% of frit B, 2-5% of sintered zinc oxide, 10-14% of sintered talc, 6-10% of wollastonite, 7-10% of high-white kaolin and 1-3% of strontium carbonate
The solvent consists of the following components in percentage by weight:
20-50% of glycerol, 45-79% of ethylene glycol and 1-5% of water-retaining solution;
the roller for printing the matt transparent glaze is a silica gel foaming adhesive roller, and the Shore hardness of a surface adhesive sheet is 8-10 degrees; the roller adopts a laser 03 or laser 04 double-engraving method, namely, the laser engraves in the same hole for two times continuously, the design gray level of the engraved pattern is 80-100%, the depth of the engraved hole is 300-500 mu m, and the aperture size is 0.3-0.4 mm.
9. The thin ceramic rock plate of claim 8, wherein the frit a has a chemical composition consisting of, in weight percent:
SiO253～54.5%、Al2O321～23.5%、Fe2O30.05～0.10%、CaO14.35～15.65%、MgO0.1～0.21%、K2O3.0～3.6%、Na2O2.3～2.7%、B2O31.7～2.0%、ZnO0.3～0.5%；
the frit B comprises the following chemical components in percentage by weight:
SiO250～51%、Al2O311～14%、Fe2O30.05～0.08%、CaO6.0～7.5%、MgO0.10～0.2%、K2O2.8～4.0%、Na2O2～3.3%、BaO9～10%、ZnO15～16.5%。
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