CN111516131B - Preparation method of porcelain archaized brick - Google Patents
Preparation method of porcelain archaized brick Download PDFInfo
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- CN111516131B CN111516131B CN202010638229.3A CN202010638229A CN111516131B CN 111516131 B CN111516131 B CN 111516131B CN 202010638229 A CN202010638229 A CN 202010638229A CN 111516131 B CN111516131 B CN 111516131B
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- 239000011449 brick Substances 0.000 title claims abstract description 38
- 229910052573 porcelain Inorganic materials 0.000 title claims abstract description 22
- 238000002360 preparation method Methods 0.000 title claims abstract description 7
- 239000000919 ceramic Substances 0.000 claims abstract description 43
- 238000000034 method Methods 0.000 claims abstract description 38
- 238000007639 printing Methods 0.000 claims abstract description 28
- 238000003825 pressing Methods 0.000 claims abstract description 16
- 238000012545 processing Methods 0.000 claims abstract description 11
- 238000007641 inkjet printing Methods 0.000 claims abstract description 6
- 238000001035 drying Methods 0.000 claims abstract description 5
- 238000000465 moulding Methods 0.000 claims abstract description 4
- 238000005245 sintering Methods 0.000 claims abstract description 4
- 239000000463 material Substances 0.000 claims abstract description 3
- 230000000694 effects Effects 0.000 claims description 13
- 238000010304 firing Methods 0.000 claims description 12
- 239000002023 wood Substances 0.000 claims description 9
- 239000007921 spray Substances 0.000 claims description 4
- 238000013461 design Methods 0.000 abstract description 6
- 238000004519 manufacturing process Methods 0.000 description 21
- 238000010521 absorption reaction Methods 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 230000007547 defect Effects 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 2
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 239000004927 clay Substances 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 239000011457 extruded brick Substances 0.000 description 1
- 239000002241 glass-ceramic Substances 0.000 description 1
- 230000004807 localization Effects 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 238000010020 roller printing Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/001—Applying decorations on shaped articles, e.g. by painting
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Structural Engineering (AREA)
- Press-Shaping Or Shaping Using Conveyers (AREA)
Abstract
The invention discloses a preparation method of a porcelain archaized brick, which comprises the following process steps: batching → homogenizing of mixed materials → dry pressing molding → pattern printing → drying → sintering; in the dry pressing and forming stage, a pressing machine only uses a plane mould to press the blank to obtain a plane blank; in the pattern printing stage, carrying out mold pattern design through a computer to obtain a mold picture, then carrying out gray processing to form a mold negative, inputting the mold negative into a ceramic ink-jet printer, and carrying out digital glaze printing on a planar blank by using a large-ink-volume nozzle to obtain a glaze pattern blank; inputting the die picture into a ceramic ink-jet printer, and carrying out digital ink-jet printing on the glaze pattern blank to obtain a double-layer pattern blank; and finally, digitally printing transparent glaze on the double-layer pattern blank to obtain a three-layer pattern blank. The advantages are that: the press working section only needs to form a plane die, and does not need to be stopped to replace other special-shaped dies, so that the time is saved, and the yield is improved.
Description
Technical Field
The invention relates to the technical field of building ceramic tiles, in particular to a production process for porcelain archaized tiles.
Background
Ceramic tiles are thin sheet products made of clay and other inorganic non-metallic materials, and are mainly used as decorations to be laid on wall surfaces and ground surfaces. Ceramic tiles are generally formed by extrusion molding at room temperature, drying, and firing at a temperature that meets performance requirements. The ceramic tile can be divided into an extruded brick and a semi-dry brick according to a forming method, and can be divided into a low water absorption brick (E is less than or equal to 3%), a medium water absorption brick (E is less than or equal to 3% and less than or equal to 10%) and a high water absorption brick (E is more than 10%) according to water absorption. In the industry, low water absorption ceramic tiles are generally classified into three major products, namely ceramic polished tiles, ceramic antique tiles and microcrystalline glass ceramic composite boards according to different production processes of the ceramic tiles.
The porcelain archaized brick is a ceramic brick product popular in recent years, the requirement of a blank body on raw materials in the production process of the porcelain archaized brick is not high, the porcelain archaized brick can be made of a ceramic material with low price, the glaze with higher whiteness is not needed like products such as porcelain full-polishing glaze in the glazing process, the surface defect of the products is not obvious, the comprehensive excellent rate is high, and the production cost is not high. In recent years, with the popularization of ceramic ink-jet printing technology and the localization of ink-jet equipment, ceramic glaze and ceramic ink, the patterns and colors of ceramic antique brick products are more and more abundant, the texture of the products is more and more vivid, the cost performance of the products is greatly improved, and the products are loved by numerous consumers by combining with the current simple and modern aesthetic styles and become the most popular and popular products at present.
After the green brick is pressed and formed, the porcelain archaized brick is subjected to a process of applying ground glaze, a process of roller printing or a process of ink-jet printing, then a layer of transparent glaze (raw glaze or fritted glaze) or a layer of transparent fritted dry particles is applied on the surface, and finally the porcelain archaized brick is put into a kiln for high-temperature firing. In the extrusion molding process of a green brick of a traditional porcelain archaized brick, a plane die or a special-shaped die (the die surface is a general name of a die with specific pattern lines) is usually used for decorating the concave-convex effect and hand feeling required by the brick surface. However, the traditional green brick pressing and forming mode has the following defects: each press can only be provided with one mould once, and because the ceramic antique brick in the market has the characteristics of small single order and frequent production change in actual production, the time consumed by the press to stop and replace the mould is very long, so that the production continuity is very poor. And the defects of layering, brick cracking and the like are easy to occur in the process of replacing the die, so that the product quality is unstable, and a large amount of waste is caused. On the other hand, in order to pursue distinctive personalized textures, the porcelain archaized bricks are large in the number of different molds, a single product relates to 3-6 molds with different effects, and each mold needs to spend a large amount of time and money cost from carving, testing to manufacturing. The problem that the mold and the design pattern cannot be matched accurately exists, and the design texture of the product cannot be well restored.
Disclosure of Invention
In order to solve the defects of frequent die production change, poor production continuity and incapability of realizing accurate matching of patterns and dies in green brick press forming of the conventional porcelain archaized brick, the invention provides a brand-new production process of the porcelain archaized brick, which has the following scheme:
a preparation method of porcelain archaized brick comprises the following process steps: batching → homogenizing of mixed materials → dry pressing molding → pattern printing → drying → sintering; the method is characterized in that the specific process steps of dry pressing and pattern printing are as follows:
(1) in the dry pressing and forming stage, a pressing machine only uses a plane mould to press the blank to obtain a plane blank;
(2) designing a mold pattern through a computer, drawing the mold pattern on a planar mold needing pattern matching to obtain an original mold picture, and performing gray processing on the mold picture to form a mold negative;
(3) inputting the mold bottom sheet into a ceramic ink-jet printer, and performing digital glaze printing on the planar blank by using a large-ink-volume nozzle to enable the planar blank to have the texture effect of a pattern mold, so as to obtain a glaze pattern blank;
(4) inputting an original mould picture into a ceramic ink-jet printer, performing digital ink-jet printing on a glaze pattern blank, covering the pattern of the mould picture on the glaze pattern blank to obtain a double-layer pattern blank, and realizing the alignment matching of the original mould picture and the glaze pattern blank during printing;
(5) inputting the die bottom sheet into a ceramic ink-jet printer, performing digital printing of transparent glaze on the double-layer pattern blank by using a large-ink-volume spray head, and covering the transparent glaze on the double-layer pattern blank to obtain a three-layer pattern blank.
Further, in the process step (2), the outlines and the textures in the mold patterns are extracted, and gray level processing is performed through Photoshop software to form a mold negative film with wood grains. The mold pattern may also be any other artistic creation pattern.
Further, in the process step (2), the mold pattern is wood grain, the bark and the annual ring grains in the mold pattern are extracted, and the mold bottom sheet with the wood grain is formed by performing gray processing through Photoshop software.
Further, in the process step (3), the mold negative is matched with various special-shaped molds, so that the effect that the same mold pattern corresponds to various special-shaped molds is realized.
Furthermore, in the step (5), the transparent glaze is printed by matching three glazes with different firing temperatures, and the glazes with the specified firing temperature are used at different positions on the same double-layer pattern blank, so that the ceramic archaized brick obtained after firing has different hand feeling and glossiness.
The principles of the invention for improving the production continuity of the porcelain archaized brick and accurately matching the mould are as follows: the texture effect of the pattern mold on the surface of the green body is realized by a way of digitally printing and glazing through a ceramic ink-jet printer, after a ceramic ink-jet printer sprays digital glaze, pattern printing is carried out on the green brick through a second ceramic ink-jet printer, transparent glaze printing is carried out through a third ceramic ink-jet printer, and the three ceramic ink-jet printers use the same set of original mold pattern design file to realize accurate alignment of the pattern and a planar mold, so that multiple printing dislocation is avoided; three ceramic ink-jet printers can also use mould patterns with different design contents to carry out art matching, namely pattern superposition, so as to achieve ever-changing artistic effect.
From the above, compared with the prior art, the invention has the following advantages: in the dry pressing and forming stage, the press only needs to install a formed plane die, the texture effect of the pattern die on the surface of the blank is realized by a digital printing glazing way of a ceramic ink-jet printer, and the cost of the special-shaped die is saved by more than 90 percent; the machine does not need to be stopped to replace other special-shaped molds, so that a large amount of time for replacing the molds is saved, and the time for replacing the molds is saved by over 90 percent; the method can be quickly adapted to frequent production change, has good production continuity, avoids printing dislocation for many times due to accurate matching of the patterns and the plane die, and improves the yield; the production line is more flexible in production and the unit cost of the product is reduced.
Drawings
FIG. 1 is a process flow diagram of a preferred embodiment of the present invention.
Detailed Description
The invention and its advantageous technical effects are explained in further detail below with reference to the drawings and preferred embodiments. The ceramic inkjet printer according to the present embodiment may be a commercially available ceramic inkjet printer, and the head is preferably a starlight 1024L head or an RC1536L head.
The preparation method of the porcelain archaized brick preferably implemented by the invention comprises the following process steps: batching S1 → homogenizing of the batch S2 → dry press molding S3 → pattern printing S4 → drying S5 → firing S6; the method is characterized in that the specific process steps of the dry pressing forming S3 and the pattern printing S4 are as follows:
(1) in the dry pressing and forming stage, a pressing machine only uses a plane mould to press the blank to obtain a plane blank;
(2) designing a mold pattern through a computer, drawing the mold pattern on a planar mold needing pattern matching to obtain an original mold picture, and performing gray processing on the mold picture to form a mold negative;
(3) inputting the mold bottom sheet into a ceramic ink-jet printer, and performing digital glaze printing on the planar blank by using a large-ink-volume nozzle to enable the planar blank to have the texture effect of a pattern mold, so as to obtain a glaze pattern blank; the mould pattern can also be any other artistic creation pattern;
(4) inputting an original mould picture into a ceramic ink-jet printer, performing digital ink-jet printing on a glaze pattern blank, covering the pattern of the mould picture on the glaze pattern blank to obtain a double-layer pattern blank, and realizing the alignment matching of the original mould picture and the glaze pattern blank during printing; or other arbitrary artistic creation patterns are matched arbitrarily to obtain other unexpected diversified 'mask' pattern superposition artistic effects;
(5) inputting the die bottom sheet into a ceramic ink-jet printer, performing digital printing of transparent glaze on the double-layer pattern blank by using a large-ink-volume spray head, and covering the transparent glaze on the double-layer pattern blank to obtain a three-layer pattern blank.
Preferably, in the process step (2), the outlines and the textures in the mold patterns are extracted, and the mold negative film with the wood grains is formed by performing gray processing through Photoshop software.
Preferably, in the process step (2), the mold pattern is wood grain, the bark and the annual ring texture in the mold pattern are extracted, and the mold negative with wood grain is formed by performing gray processing through Photoshop software.
In addition, as an extended application, preferably, in the process step (3), the mold base plate is matched with various special-shaped molds, so that the effect that the same mold pattern corresponds to various special-shaped molds is achieved.
As a specific implementation manner, preferably, in the process step (5), the transparent glaze is printed by matching three glazes with different firing temperatures, and the glazes with the specified firing temperature are used at different positions on the same double-layer pattern blank, so that the ceramic archaized brick obtained after firing has different hand feeling and glossiness.
When production is carried out, a corresponding production line can be manufactured according to the flow of the process steps, three printers of a ceramic ink-jet printer can be arranged in the process step of pattern printing S4, after one ceramic ink-jet printer finishes spraying digital glaze, a second ceramic ink-jet printer carries out pattern printing on a green brick, a third ceramic ink-jet printer carries out transparent glaze printing, and the three ceramic ink-jet printers use the same set of original mold pattern design file to realize accurate alignment of the pattern of the mold picture and the planar mold; or can be combined and matched with other die pictures at will to obtain rich surface effects. In addition, other processes are carried out according to the preparation process of the porcelain archaized brick in the prior art, and other process conditions including the sintering temperature are not further described.
Because the function of the special-shaped mold is realized by combining the planar mold with the ceramic ink-jet printer, the replacement of the product pattern can be completed only on a computer, and the machine does not need to be stopped to replace other special-shaped molds, so that the cost of the special-shaped mold is saved by more than 90 percent; thereby saving a large amount of time for replacing the die and saving the time for replacing the die by more than 90 percent; the method can be quickly adapted to frequent production change, has good production continuity, and can accurately match patterns with the planar die, the yield is improved, the unit cost of the product is reduced by more than 30%, and the utilization rate of the production line is improved by more than 50%.
In the above description, details, such as structures and processes, which are conventionally used in the prior art, are not repeated for brevity. The processing technology and parts which are not disclosed by the invention are processed according to the conventional technology in the prior art.
The invention is not limited in any way by the above description and the specific examples, which are not limited to the specific embodiments disclosed and described above, but rather, several modifications and variations of the invention are possible within the scope of the invention as defined in the claims.
Claims (4)
1. A preparation method of porcelain archaized brick comprises the following process steps: batching → homogenizing of mixed materials → dry pressing molding → pattern printing → drying → sintering; the method is characterized in that the specific process steps of dry pressing and pattern printing are as follows:
(1) in the dry pressing and forming stage, a pressing machine only uses a plane mould to press the blank to obtain a plane blank;
(2) designing a mold pattern through a computer, drawing the mold pattern on a planar mold needing pattern matching to obtain an original mold picture, and performing gray processing on the mold picture to form a mold negative;
(3) inputting the mold bottom sheet into a ceramic ink-jet printer, and performing digital glaze printing on the planar blank by using a large-ink-volume nozzle to enable the planar blank to have the texture effect of a pattern mold, so as to obtain a glaze pattern blank;
(4) inputting an original mould picture into a ceramic ink-jet printer, performing digital ink-jet printing on a glaze pattern blank, covering the pattern of the mould picture on the glaze pattern blank to obtain a double-layer pattern blank, and realizing the alignment matching of the original mould picture and the glaze pattern blank during printing;
(5) inputting the die bottom sheet into a ceramic ink-jet printer, performing digital printing of transparent glaze on the double-layer pattern blank by using a large-ink-volume spray head, and covering the transparent glaze on the double-layer pattern blank to obtain a three-layer pattern blank.
2. The method for preparing a porcelain archaized brick according to claim 1, which is characterized in that: in the process step (2), the outline and the texture in the mold pattern are extracted, and the mold negative with the wood grain is formed by performing gray processing through Photoshop software.
3. The method for preparing a porcelain archaized brick according to claim 2, wherein the method comprises the following steps: in the process step (2), the mold pattern is wood grain, the bark and the annual ring grains in the mold pattern are extracted, and the mold bottom plate with the wood grain is formed by performing gray level processing through Photoshop software.
4. The method for preparing a porcelain archaized brick according to claim 1, which is characterized in that: in the step (5), the transparent glaze is printed by matching three glazes with different firing temperatures, and the glaze with the specified firing temperature is used at different positions on the same double-layer pattern blank, so that the ceramic archaized brick obtained after firing has different hand feeling and glossiness.
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| CN202010638229.3A CN111516131B (en) | 2020-07-06 | 2020-07-06 | Preparation method of porcelain archaized brick |
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| CN202010638229.3A CN111516131B (en) | 2020-07-06 | 2020-07-06 | Preparation method of porcelain archaized brick |
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| CN112374914B (en) * | 2020-11-02 | 2023-05-19 | 陶丽西(苏州)陶瓷釉色料有限公司 | Ceramic tile structure with concave-convex textures and manufacturing process thereof |
| CN112479745B (en) * | 2020-11-10 | 2022-12-13 | 广西欧神诺陶瓷有限公司 | High-simulation ceramic tile and manufacturing process and application thereof |
| CN113305992B (en) * | 2021-06-21 | 2022-07-08 | 广东家美陶瓷有限公司 | Preparation method and control method of dark black full-glazed digital decorative ceramic tile |
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| CN105924134B (en) * | 2016-04-25 | 2018-05-25 | 广东宏宇新型材料有限公司 | There is resource-conserving glazed tile of pearly-lustre and color changeable effect and preparation method thereof on surface |
| CN108117413A (en) * | 2017-12-28 | 2018-06-05 | 唐山中陶实业有限公司 | The manufacturing method of Ceramic Tiles and a kind of Ceramic Tiles |
| CN108394008A (en) * | 2018-03-23 | 2018-08-14 | 广东萨米特陶瓷有限公司 | Big plate of ceramics of anhydrous glaze line full digital code jet printing technique and preparation method thereof |
| IT201800008069A1 (en) * | 2018-08-10 | 2020-02-10 | Projecta Eng Srl | MODULAR PRINTER MACHINE FOR CERAMIC PRODUCTS |
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