CN112479745B - High-simulation ceramic tile and manufacturing process and application thereof - Google Patents
High-simulation ceramic tile and manufacturing process and application thereof Download PDFInfo
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- CN112479745B CN112479745B CN202011249382.3A CN202011249382A CN112479745B CN 112479745 B CN112479745 B CN 112479745B CN 202011249382 A CN202011249382 A CN 202011249382A CN 112479745 B CN112479745 B CN 112479745B
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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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- G06—COMPUTING; CALCULATING OR COUNTING
- G06F—ELECTRIC DIGITAL DATA PROCESSING
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06T—IMAGE DATA PROCESSING OR GENERATION, IN GENERAL
- G06T7/00—Image analysis
- G06T7/90—Determination of colour characteristics
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Abstract
The invention belongs to the technical field of architectural ceramics, and discloses a high-simulation ceramic tile and a manufacturing process and application thereof. In actual operation, the white ink usage amount and the whiteness information corresponding to the average gray value can be obtained from the whiteness mapping database only according to the average gray value of the pattern information, so that the white ink with the corresponding whiteness and the corresponding usage amount is applied to the ceramic tile glaze, and printing can be performed. Therefore, the method can be used for realizing the overall adjustment and the local adjustment of the image and improving the depth of field effect, and simultaneously can reduce the using amount of the high-white glaze. The ceramic tile obtained by the invention can achieve high simulation effect, can be used in the fields of building, decoration and the like, and has wide influence before application.
Description
Technical Field
The invention belongs to the technical field of architectural ceramics, and particularly relates to a high-simulation ceramic tile and a manufacturing process and application thereof.
Background
With the improvement of living standard of people, consumers have higher and higher requirements on the surface decoration effect of ceramic tiles, and marble ceramic tiles with high simulation pattern effect become the mainstream of the market. At present, under the promotion and assistance of an ink-jet printing technology, the simulation effect of the marble ceramic tile is more and more close to the actual pattern effect, but because the pattern is printed on the overglaze in the manufacturing process of the current glazed tile, the brightness degree of the background on the finally obtained whole tile surface is basically consistent, the ceramic tile pattern lacks the depth of field effect, the brightness degree of the background of the original image at different positions can not be realized to realize the differentiation effect, and the simulation degree of the ceramic tile pattern needs to be further improved.
Disclosure of Invention
The invention provides a high-simulation ceramic tile and a manufacturing process and application thereof, which are used for solving one or more technical problems in the prior art and at least providing a beneficial selection or creation condition.
In order to overcome the technical problems, the technical scheme adopted by the invention is as follows:
a manufacturing process of a high-simulation ceramic tile comprises the step of printing white ink on the glaze surface of the ceramic tile, and the step comprises the establishment of a whiteness mapping database, wherein the whiteness mapping database is obtained by the following method:
1) Acquiring images of a plurality of samples;
2) Respectively reading the average gray value of each image;
3) Printing each image on the glazed surface of the ceramic tile to obtain the consumption of white ink consumed respectively;
4) After the image printing is finished, sintering, and respectively measuring the whiteness information of the fired ceramic tile glaze;
5) And inputting the average gray value of each image and the corresponding white ink usage amount and whiteness information into a whiteness mapping database to obtain a whiteness mapping database.
The average gray value is the average gray value of all pixel points of the image. The gray value can be adjusted according to the required depth of field effect, the similarity between the printed image and the actual image after being sintered is improved, and the simulation degree of the product pattern is improved;
the image of the sample is the target image for printing on the tile glaze.
As a further improvement of the above scheme, in step 1), the image is obtained by taking a picture, preferably by taking a high-definition picture (instant completion), so that distortion caused by light and voltage fluctuation in the scanning process of the scanner can be effectively avoided.
As a further improvement of the above scheme, in step 2), design software is used to obtain the average gray value, including photoshop, etc.
As a further improvement of the above scheme, in step 5), the whiteness degree mapping database is established in an inkjet printing system. The ink-jet printing system is software matched with a printer.
As a further improvement of the above scheme, the step of printing an image on a glazed surface of a ceramic tile further includes, after the whiteness degree mapping database is established, printing an image on the glazed surface of the ceramic tile according to the whiteness degree mapping database, and processing in the following manner:
6) Inputting an image to be printed;
7) Reading the average gray value of an image to be printed;
8) Obtaining whiteness information and white ink usage amount respectively corresponding to the average gray value according to a whiteness mapping database, and printing white ink;
9) And (5) applying colored glaze.
As a further improvement of the above scheme, in step 8), after obtaining the white ink usage, judging before printing: when the white ink usage exceeds a preset value, adjusting the average gray value of the image to be printed, and obtaining the white ink usage and the whiteness information corresponding to the average gray value according to a whiteness mapping database, wherein the preset value is 0-40g/m 2 Wherein the white ink is used in an amount of more than 40g/m 2 After that, there is hardly any help to increase the whiteness of the glaze. The higher the whiteness of the overglaze is, the more bright the color of the glaze adhered to the surface of the overglaze after high-temperature sintering is, the more beautiful the color can be restored, thereby effectively avoiding the distortion of the pattern and improving the consistency of the sintered pattern and the original pattern.
As a further improvement of the above, an inkjet printer is used to print white ink.
As a further improvement of the above solution, the number of channels of the inkjet printer is several columns, preferably 10 or more columns. To meet the multiple color requirements in the image.
A high simulation ceramic tile is prepared by the manufacturing process.
The high-simulation ceramic tile disclosed by the invention is applied to the fields of construction, decoration and the like.
The invention has the beneficial effects that:
(1) The invention provides a high-simulation ceramic tile and a manufacturing process and application thereof, which comprises the step of printing an image on a ceramic tile glaze, wherein the step comprises the establishment of a whiteness mapping database and the image printing on the ceramic tile glaze according to the whiteness mapping database.
(2) In actual operation, the white ink usage amount and the whiteness information corresponding to the average gray value can be obtained from the whiteness mapping database only according to the average gray value of the pattern information, so that the white ink with the corresponding whiteness and the corresponding usage amount is applied to the ceramic tile glaze, and printing can be performed. Therefore, when the change of the integral brightness (gray scale) of the image is required, the adjustment and the change can be carried out according to the actual pattern or the requirement; secondly, the whiteness difference of the ceramic tile overglaze is changed, so that the depth of field effect of image restoration can be improved, the simulation degree of the image is improved, the distortion is reduced, and the consistency of the ceramic pattern before and after adjustment is ensured; thirdly, according to the invention, white ink with a corresponding average gray value can be applied to the local part of the common glaze according to the requirement so as to increase the brightness of the glaze, thereby greatly reducing the use amount of the glaze and achieving the effects of saving glaze resources and the like; in addition, under the condition of higher overall brightness requirement, glaze with lower whiteness can be adopted, and after the overglaze is obtained, the white ink is quantitatively printed on the overglaze according to the requirement, so that higher brightness can be realized, the thickness of the glaze is greatly reduced, and the cost of the glaze (the price of the high-white glaze is high).
(3) The ceramic tile obtained by the invention can achieve high simulation effect, can be used in the fields of building, decoration and the like, and has wide application prospect.
Drawings
In order to more clearly illustrate the technical solution in the embodiments of the present invention, the drawings used in the description of the embodiments will be briefly described below. It is clear that the described figures are only some embodiments of the invention, not all embodiments, and that a person skilled in the art can also derive other designs and figures from them without inventive effort.
FIG. 1 is a graph comparing the results of the surface finish of the ceramic tile obtained in case 3 of example 1;
FIG. 2 is a photograph of the finished ceramic tile obtained in example 2 and comparative example 1, respectively, in the presence or absence of white ink;
FIG. 3 is a photograph of the finished ceramic tile obtained in example 3 and comparative example 2, respectively, in the presence or absence of white ink.
Detailed Description
The present invention is specifically described below with reference to examples in order to facilitate understanding of the present invention by those skilled in the art. It should be particularly noted that the examples are given solely for the purpose of illustration and are not to be construed as limitations on the scope of the invention, as non-essential improvements and modifications to the invention may occur to those skilled in the art, which fall within the scope of the invention as defined by the appended claims. Meanwhile, the raw materials mentioned below are not specified in detail and are all commercially available products; the process steps or extraction methods not mentioned in detail are all process steps or extraction methods known to the person skilled in the art.
Example 1
A manufacturing process of a high-simulation ceramic tile comprises the step of printing an image on the ceramic tile glaze, wherein the step comprises the steps of establishing a whiteness mapping database and printing the image on the ceramic tile glaze according to the whiteness mapping database, and the whiteness mapping database is obtained by the following method:
1) Acquiring images of a plurality of samples in a high-definition photographing (instant finishing) mode;
2) Respectively reading the average gray value of each image by adopting photoshop design software;
3) Printing each image on the glazed surface of the ceramic tile to obtain the consumption of white ink consumed respectively;
4) After the image printing is finished, sintering, and respectively measuring the whiteness information of the fired ceramic tile glaze;
5) And inputting the average gray value of each image and the corresponding white ink usage amount and whiteness information into the ink-jet printing system, and establishing and obtaining a whiteness mapping database.
After the whiteness mapping database is established, the step of printing the image on the glazed surface of the ceramic tile further comprises the step of printing the image on the glazed surface of the ceramic tile according to the whiteness mapping database, and the image is processed in the following mode:
6) Inputting an image to be printed;
7) Reading the average gray value of an image to be printed;
8) Obtaining whiteness information and white ink usage amount respectively corresponding to the average gray value according to a whiteness mapping database, and then printing by adopting an ink-jet printer, wherein the number of channels of the ink-jet printer is more than 10 columns, and when the white ink usage amount exceeds a preset value, the white ink usage amount is 0-40g/m 2 And adjusting the average gray value of the image to be printed, and obtaining the white ink usage amount and the whiteness information corresponding to the average gray value according to the whiteness mapping database to finally obtain the ceramic tile with the glaze surface having the high simulation effect.
The whiteness map database is shown in table 1 below.
TABLE 1
The present invention can achieve the following 4 cases.
Case 1: when the adjustment of the integral brightness (gray scale) of the image is needed, the adjustment and the change can be carried out according to the actual pattern or the requirement;
case 2: the method can also be used for improving the depth of field effect of image reduction by changing the whiteness difference of ceramic tile overglaze, thereby improving the simulation degree of the image, reducing distortion and ensuring the consistency of ceramic patterns before and after adjustment;
case 3: the invention can also apply white ink corresponding to the average gray value on the local part of the common glaze according to the requirement to increase the brightness of the glaze, thereby greatly reducing the using amount of the glaze and achieving the effects of saving the glaze resource and the like;
case 4: under the condition of high overall brightness requirement, glaze with low whiteness can be adopted, and after overglaze is obtained, white ink is printed on the overglaze quantitatively according to requirements, so that higher brightness can be realized, the thickness of the glaze is greatly reduced, and the cost of the glaze is reduced (the price of high-white glaze is high).
Wherein, fig. 1 is a comparison graph of the effect of the situation 3, and as can be seen from fig. 1, the depth of field effect of the picture after the picture is printed on the finished product of the surface of the ceramic tile is obviously better than that of the right part without white ink on the left part where the white ink is applied. However, the high-white glaze used for increasing brightness is expensive, and the left part with white ink in fig. 1 can achieve the same brightness effect even better after white ink is applied (cheap), so that the effect of greatly saving glaze resources can be achieved, and the economic benefit is also improved on the premise of ensuring the picture quality of the ceramic tile surface. Cases 1, 2 and 4, the same principle and effect as in case 3.
Example 2
A manufacturing process of a high-simulation ceramic tile comprises the step of printing an image on the ceramic tile glaze, wherein the step comprises the steps of establishing a whiteness mapping database and printing the image on the ceramic tile glaze according to the whiteness mapping database, wherein the whiteness mapping database is obtained in a mode determined in embodiment 1:
after the whiteness mapping database is established, the step of printing the image on the glazed surface of the ceramic tile further comprises the step of printing the image on the glazed surface of the ceramic tile according to the whiteness mapping database, and the image is processed in the following mode:
1) Inputting an image to be printed;
2) Directly printing patterns on the glaze surface which is not sprayed with the white ink;
3) At a ratio of 30g/m 2 Uniformly spraying white ink on the glaze according to the proportion, and then directly printing a pattern (which is consistent with the pattern in the step 2) on the glaze sprayed with the white ink;
4) And (4) putting the product printed with the patterns in the step (2) and the step (3) into a kiln for firing to obtain a finished product.
Comparative example 1
Comparative example 1 differs from example 2 only in that comparative example 1 did not spray the white ink.
FIG. 2 is a photograph of a finished ceramic tile obtained in the presence or absence of white ink according to example 2 and comparative example 1, wherein a is a photograph of the finished ceramic tile of example 2 and b is a photograph of the finished ceramic tile of comparative example 1; from a, compared with the pattern without the white ink sprayed on b, the pattern sprayed with the white ink has higher definition and stronger layering, wherein the whiteness of the white stripe without the white ink is 63 degrees (white part), and the whiteness of the white product sprayed with the white ink reaches 85 degrees; in other parts, the same pattern and the same ink consumption, compared with the part without white ink, the white ink applied part has brighter pattern, stronger pattern layering sense and better depth of field effect.
Example 3
A manufacturing process of a high-simulation ceramic tile comprises the step of printing an image on a ceramic tile glaze, wherein the step comprises the steps of establishing a whiteness mapping database and printing the image on the ceramic tile glaze according to the whiteness mapping database, wherein the whiteness mapping database is obtained by the following method:
1) Acquiring images of a plurality of samples in a high-definition photographing (instant finishing) mode;
2) Respectively reading the average gray value of each image by adopting photoshop design software;
3) Printing each image on the glazed surface of the ceramic tile to obtain the consumption of white ink consumed respectively;
4) Drying, grinding, water spraying and surface glaze applying are carried out on the pressed green bricks to obtain glaze biscuit, and the green bricks with the surface glaze are conveyed to an ink-jet printer;
5) And applying different amounts of white ink on different areas of the surface of the brick by the ink-jet printer according to the obtained whiteness information corresponding to different positions on the glaze surface, then printing the image, and conveying the printed biscuit into a kiln for sintering to obtain the ceramic brick applying the white ink according to the picture brightness.
Comparative example 2
The difference between the comparative example 2 and the example 3 is that in the preparation process of the ceramic tile, the pattern brightness information is in a closed state, the ink-jet printer only prints the pattern on the glaze surface, and then the biscuit printed with the pattern is sent into a kiln to be fired, so that the ceramic tile without white ink application is obtained, namely the ceramic tile finished product without white ink application is obtained by not spraying white ink on the comparative example 2.
FIG. 3 is a photograph of the ceramic tile product of example 3 and comparative example 2, respectively, in the presence or absence of white ink, wherein a is a photograph of the ceramic tile product of example 3 and b is a photograph of the ceramic tile product of comparative example 2; as can be seen from fig. 3, in example 3, by comparing the ceramic tile obtained by applying white ink according to different brightness in different areas of the image (example 3) with the ceramic tile obtained without applying white ink (comparative example 2), it can be found that the ceramic tile applied with white ink according to different brightness (example 3) has stronger layering, the depth of field effect of the ceramic tile is better than that of the ceramic tile without white ink (comparative example 2), the image details are more abundant, and the original effect of the pattern can be more strongly restored.
It will be obvious to those skilled in the art that many simple derivations or substitutions can be made without inventive effort without departing from the inventive concept. Therefore, simple modifications to the present invention by those skilled in the art according to the present disclosure should be within the scope of the present invention. The above embodiments are preferred embodiments of the present invention, and all similar processes and equivalent variations to those of the present invention should fall within the scope of the present invention.
Claims (8)
1. The manufacturing process of the high-simulation ceramic tile is characterized by comprising the step of printing an image on the glazed surface of the ceramic tile, wherein the step comprises the steps of establishing a whiteness mapping database and printing the image on the glazed surface of the ceramic tile according to the whiteness mapping database, and the manufacturing process is specifically obtained by the following steps:
1) Acquiring images of a plurality of samples;
2) Respectively reading the average gray value of each image;
3) Printing each image on the glazed surface of the ceramic tile to obtain the consumption of white ink consumed respectively;
4) After the image printing is finished, sintering, and respectively measuring the whiteness information of the fired ceramic tile glaze;
5) Inputting the average gray value of each image and the corresponding white ink usage amount and whiteness information into a whiteness mapping database to obtain a whiteness mapping database;
6) Inputting an image to be printed;
7) Reading the average gray value of an image to be printed;
8) Obtaining whiteness information and white ink usage amount respectively corresponding to the average gray value according to a whiteness mapping database, and printing white ink;
9) Coating colored glaze;
in step 8), judging before printing after obtaining the white ink consumption: when the white ink usage exceeds a preset value, adjusting the average gray value of the image to be printed, and obtaining the white ink usage and the whiteness information corresponding to the average gray value according to the whiteness mapping database, wherein the preset value is 0-40g/m 2 。
2. The manufacturing process according to claim 1, wherein in step 1), the image is obtained by taking a photograph.
3. The manufacturing process according to claim 1, wherein in step 2), the average gray-scale value is obtained by using design software.
4. A manufacturing process according to claim 1, wherein in step 5), the whiteness map database is established in an inkjet printing system.
5. The process of claim 1, wherein the white ink is printed using an ink jet printer.
6. The process according to claim 5, wherein the number of channels of the ink jet printer is 10 or more columns.
7. A high simulation ceramic tile, characterized by being produced by a production process comprising any one of claims 1 to 6.
8. The use of the high simulation ceramic tile of claim 7 in the construction and finishing field.
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