CN113305993A - Engraved mercerized glazed tile and production method thereof - Google Patents
Engraved mercerized glazed tile and production method thereof Download PDFInfo
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- CN113305993A CN113305993A CN202110703401.3A CN202110703401A CN113305993A CN 113305993 A CN113305993 A CN 113305993A CN 202110703401 A CN202110703401 A CN 202110703401A CN 113305993 A CN113305993 A CN 113305993A
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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
- 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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- 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
- B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
- B28B11/044—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers with glaze or engobe or enamel or varnish
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B44—DECORATIVE ARTS
- B44F—SPECIAL DESIGNS OR PICTURES
- B44F9/00—Designs imitating natural patterns
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
- C03C8/14—Glass frit mixtures having non-frit additions, e.g. opacifiers, colorants, mill-additions
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
- C03C8/14—Glass frit mixtures having non-frit additions, e.g. opacifiers, colorants, mill-additions
- C03C8/20—Glass frit mixtures having non-frit additions, e.g. opacifiers, colorants, mill-additions containing titanium compounds; containing zirconium compounds
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
- C03C8/22—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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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D11/00—Inks
- C09D11/30—Inkjet printing inks
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- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
- C09D11/00—Inks
- C09D11/30—Inkjet printing inks
- C09D11/38—Inkjet printing inks characterised by non-macromolecular additives other than solvents, pigments or dyes
Abstract
The invention discloses a carved mercerized glazed tile and a production method thereof; the engraved mercerized glazed tile is prepared by firing a porcelain tile blank, then applying a ground glaze, applying a cover glaze on the ground glaze, then drying, printing color ink and functional ink by a digital ink-jet printer, then drying, spraying protective glaze and firing; 5 to 9 percent of ball clay is introduced into the overglaze formula, and 74 to 86 percent of transparent matte frit is introduced into the protective glaze formula. The pattern of the engraved mercerized glazed tile obtained by the invention has fine and natural texture, clear and uniform color, high simulation degree and lifelike appearance, the depth of the texture of the engraved mercerized glazed tile is 60-75 um, the fineness of the texture is as minimum as 6 pixel units under the resolution of 400, and the boundary of the texture line is clear under the resolution of 400.
Description
Technical Field
The invention relates to the field of building ceramic materials, in particular to a production method of a carved mercerized glazed tile and the glazed tile prepared by the method.
Background
The glazed tile as one of the main building decoration materials has the advantages of various styles, rich colors and patterns, convenience in cleaning, strong antifouling capacity and the like, and plays a very important role in home decoration. With the improvement of the living standard of people, the decoration requirement of people on home decoration is continuously improved, and diversification, individuation and artistry of space decoration are pursued more. In recent years, various glazed ceramic tile products are available in the market, and the aim is to pursue simulation and texture. However, most glazed products in the market only apply a layer of bright glaze or matte glaze on the inkjet printed pattern to achieve a decorative effect, and the effect of the glaze does not have diversification and reality in nature, and many special effects cannot be reflected, such as the texture of animal fur, the vein of plant epidermis, the texture of silk satin and the like.
At present, to the glazed tile that has unsmooth texture special effect pattern in surface, the printing that the traditional approach generally adopted the adobe mould to obtain the pattern texture, however the ceramic tile of different texture effects needs specific adobe mould, so not only the cost is expensive, also do not benefit to the operation, and the mould texture is too dark easy laying dust, can cause the disappearance of glaze, simultaneously because polish or blow dirt thoroughly in the glaze line process, can cause the adobe blank to appear defects such as base powder and pinhole, these all can lead to the texture pattern effect unsatisfactory, the pattern is incomplete, the texture is unclear scheduling problem.
The Chinese patent application 2019105991041 discloses a method for preparing carved magnetic wood large-plate ceramic tiles, which produces a wood grain plate with concave-convex texture on the surface by changing the thickness of glazing amount and applying corrosive carved ink, but the concave-convex texture fineness obtained by a corrosion method is difficult to control and has certain danger, and meanwhile, special texture effects such as animal fur, silk and satin are difficult to express by the method.
The chinese patent application 2019112847134, which utilizes the characteristic of ink separation between the oil property of ink and the water property of transparent glaze, makes the ink with texture pattern physically discharge the water glaze sprayed subsequently, so as to form the fine carving effect of ceramic tile with the ink texture pattern position as depression, but because of the ink diffusivity, the texture lines are fuzzy, and the stereoscopic impression is also poor. The Chinese invention patent with patent number 201710566851.6 (published 2020, 5/15) forms a simulated embossed texture by utilizing the property difference of 3D embossed ink and embossed overglaze and changing the spraying position of the 3D embossed ink and the using amount of the embossed overglaze, and the embossed texture with a good simulation effect can be obtained by utilizing the incompatibility of the 3D embossed ink and the embossed overglaze in the patent, but the fineness of the texture is low because the diffusibility of the embossed ink on the overglaze can not be well controlled, so that products with special effects similar to animal fur, plant epidermis and the like produced by the method have the advantages that the texture and the grain are not well expressed, and the obvious difference exists compared with a real object.
Disclosure of Invention
The invention aims to provide a preparation method of a glazed tile with fine and smooth texture and vivid effect and high simulation pattern and real texture effect, which is characterized in that on the basis of not making great changes on the formula and production process parameters of the existing glazed tile, the fineness and the simulation degree of the texture are further improved by adjusting and optimizing the composition of a surface glaze, a finishing carving ink, a protective glaze, and the like and combining a glaze spraying technology, an ink-jet printing machine and other equipment processes, the fineness of the texture can be as low as 6 pixel units (namely 0.38mm) under the resolution of 400, the depth of the concave texture can be as high as 60-75 microns, and the boundary of the line is clearly distinguished under the resolution of 400, so that the technical conversion from two-dimensional to multi-dimensional high simulation and real texture is realized, and the engraved glazed tile with fine and clear texture and high simulation degree is obtained.
The engraved mercerized glazed tile has fine and clear pattern texture, uniform color, strong stereoscopic impression and high simulation degree, the depth of the texture is 60-75 um, the fineness of the texture can reach 6 pixel units (namely 0.38mm) at the minimum under 400 resolution, and the boundary of the texture line is clear under 400 resolution
In the invention, engraving is a combination of a plurality of concave fine line structures formed by the reaction of refined ink carving and enameling surface and sintering; mercerization refers to the bright effect on the sintered concave lines.
The technical scheme adopted by the invention for solving the technical problems is as follows:
a carving mercerized glazed tile is prepared by biscuit firing a porcelain tile blank, then applying a ground glaze, then applying a surface glaze on the ground glaze, then drying, printing color ink and functional ink by a digital ink-jet printer, then drying, spraying protective glaze and firing; the overglaze comprises the following raw materials in percentage by mass: 5009 clinker 49 + -3%, zirconium silicate 14 + -2%, calcined alumina 15 + -2%, wollastonite powder 5 + -1%, calcined talcum powder 4 + -1%, calcined kaolin 2 + -0.2%, ball clay powder 7 + -2% and air knife soil 3 + -1%; the protective glaze comprises the following raw materials in formula: 74-86% of transparent matte frit, 10 +/-2% of zinc oxide, 2 +/-0.5% of calcined kaolin, 6 +/-2% of air knife soil and 3 +/-0.5% of ball clay.
In order to further achieve the purpose of the invention, preferably, the depth of the texture concave of the engraved mercerized glazed tile is 60-75 um, the fineness of the texture is as minimum as 6 pixel units under the resolution of 400, and the boundary of the texture line is clear under the resolution of 400.
Preferably, the transparent matte frit consists of 3019 frit 62 +/-3%, 3082 frit 11 +/-2% and 3008 frit 7 +/-1% in percentage by mass.
Preferably, the ground coat comprises the following chemical components in percentage by mass: 5.3 +/-0.3 percent of aluminum oxide, 61.0 +/-1 percent of silicon dioxide, 0.2 +/-0.01 percent of ferric oxide, 18.5 +/-0.2 percent of calcium oxide, 1.3 +/-0.2 percent of magnesium oxide, 2.5 +/-0.2 percent of potassium oxide, 1.0 +/-0.1 percent of sodium oxide, 10.0 +/-0.5 percent of titanium dioxide, 1.0 +/-0.2 percent of zinc oxide, 1.0 +/-0.2 percent of barium oxide and 0.5 +/-0.2 percent of loss on ignition.
Preferably, the chemical compositions of the carved ink in percentage by mass are 56.0 +/-2% of ignition loss (1025 ℃), 3.5 +/-0.2% of aluminum oxide, 25.0 +/-0.5% of silicon dioxide, 0.1 +/-0.01% of ferric oxide, 8.0 +/-0.2% of calcium oxide, 1.5 +/-0.2% of potassium oxide, 0.08 +/-0.02% of sodium oxide, 0.05 +/-0.01% of titanium dioxide, 0.05 +/-0.01% of phosphorus pentoxide, 5.0 +/-0.2% of zinc oxide, 0.01 +/-0.002% of lead monoxide, 0.01 +/-0.002% of sulfur trioxide, 0.05 +/-0.01% of boron trioxide, 0.05 +/-0.01% of fluorine, 0.01 +/-0.01% of lithium oxide, 0.01 +/-0.002% of strontium oxide, 0.01 +/-0.002% of manganese oxide, 0.01 +/-0.002% of cadmium oxide, 0.01 +/-0.002% of chromium oxide, 0.002% of nickel oxide, 0.01 +/-0.002% of cobalt oxide, 0.01 +/-0.002% of cesium oxide, 0.002% of cobalt oxide, 0.01 +/-0.002% of cobalt oxide.
Preferably, the protective glaze formula comprises the following chemical components in percentage by mass: 15.0 +/-0.5% of aluminum oxide, 59.0 +/-2% of silicon dioxide, 1.5 +/-0.2% of potassium oxide, 3.0 +/-0.2% of sodium oxide, 6.0 +/-1% of calcium oxide, 1.0 +/-0.2% of magnesium oxide, 7.0 +/-1% of zinc oxide, 1.2 +/-0.2% of boron oxide, 4.5 +/-0.2% of barium oxide, 1.0 +/-0.2% of strontium oxide and 0.5 +/-0.2% of loss of ignition.
Preferably, the overglaze comprises the following chemical components in percentage by mass: 29 plus or minus 2 percent of aluminum oxide, 42 plus or minus 2 percent of silicon dioxide, 0.2 plus or minus 0.01 percent of ferric oxide, 8 plus or minus 0.5 percent of calcium oxide, 2 plus or minus 0.5 percent of magnesium oxide, 2 plus or minus 0.2 percent of potassium oxide, 1.0 plus or minus 0.1 percent of sodium oxide, 6.5 plus or minus 0.2 percent of zinc oxide, 7 plus or minus 0.2 percent of boron oxide and 0.5 plus or minus 0.2 percent of loss on ignition.
Preferably, the color ink includes blue ink, brown ink, encapsulated yellow ink, encapsulated red ink, black ink and green ink; the functional ink comprises one or two of bright ink and carved ink.
The production method of the engraved mercerized glazed tile comprises the following steps:
1) pressing and molding the green body, and biscuiting the green body of the porcelain brick;
2) overglaze and ground glaze: distributing a base glaze on the ceramic tile blank through a glaze pouring device, and distributing a cover glaze on the base glaze;
3) drying before ink jetting;
4) ink-jet printing: printing color ink and functional ink in sequence by adopting a digital ink-jet printer;
5) drying after ink jetting;
6) spraying protective glaze by a glaze spraying machine, wherein the spraying amount of the protective glaze is 250 +/-5 g/m2；
7) And firing to obtain the glazed tile with the engraved mercerizing effect.
Preferably, in the step 1), the biscuit firing temperature is 1075 +/-5 ℃, and the firing period is 55 +/-5 min;
in the step 2), 610 +/-10 g/m of glaze is spread on the ceramic tile blank body through a glaze spraying device2A base coat, and then 440 +/-10 g/m of the base coat is spread on the base coat2Overglaze
In the step 3), the drying temperature is 220 +/-5 ℃, and the drying period is 90 +/-10 s;
in the step 4), the digital ink-jet printer is a novel 12-channel ink-jet printer, wherein 6 channels are color ink channels and are respectively provided with blue ink, brown ink, package yellow ink, package red ink, black ink and green ink; in addition, the 6 channels are functional ink channels, wherein the 2 channels are respectively provided with bright ink and carved ink;
in the step 5), the drying temperature is 220 +/-5 ℃, and the drying period is 120 +/-10 s;
in the step 6), spraying protective glaze by using an imported AIR POWER glaze spraying machine, wherein the spraying amount of the protective glaze is 250 +/-5 g/m when the pressure reaches more than 15bar2The specific gravity is 1.40 +/-0.03 g/ml, and the spraying flow rate is 12-15 seconds.
In the step 7), the sintering temperature is 1045 +/-5 ℃, and the sintering period is 60 +/-5 min.
The over glaze in the prior art generally uses less ball clay and uses more air knife clay, which is mainly because the air knife clay is cheaper than the ball clay, and compared with the air knife clay, the ball clay can influence the performance of the glaze slip, the viscosity of the glaze slip is high, bubbles in the glaze slip are not easy to release, pinholes or pits can be formed after glaze spraying, and in addition, the ball clay is used as plastic clay, and the content is too much (10%), so that the glaze shrinks greatly during drying, and cracks are generated on the glaze. The invention introduces reasonable ball-clay ratio (5-9%) in the overglaze formula, the reasonable ball-clay content can better avoid the defects of large drying shrinkage and high glaze slip viscosity, simultaneously the shrinkage of the glaze can be reduced by reducing the content of calcined kaolin, thereby avoiding the generation of cracks, and the stirring speed of the glaze slip is reduced to reduce bubbles, thereby avoiding the defects of pinholes, pits and the like. According to the invention, 5% -9% of ball clay is introduced into the overglaze formula, the ball clay has the water retention characteristic that air knife soil does not have, and the water retention characteristic of the ball clay ensures that the finishing carving ink cannot be rapidly diffused when printed on the overglaze, so that the line printed by the finishing carving ink cannot be widened or permeated and diffused, and the fineness of the texture line can be 6 pixel units (namely 0.38mm) at the minimum under the resolution of 400.
The engraving ink is formed by compounding a material with a good high-temperature fluxing effect and a hydrophobic material with extremely low surface tension, is a hybrid composite material, and is in a groove-shaped glaze surface form with a certain depth by the repulsion effect of the hydrophobic material and the repulsion effect of the glaze slurry generated by spraying and printing the pattern part of the engraving ink; meanwhile, in the high-temperature sintering process, the grooves formed in the glazing process are further sunk under the high-temperature melting and clouding effect of the carved ink, the decoration aesthetic feeling like natural cracks is finally formed, the glittering ink can react with the overglaze to form the gloss performance, the glittering ink is superposed on the carved ink to form brightening, the effect of metal-like gloss is formed, and the glittering ink is like a crystal line formed on the carved line, so that the effects of sinking, peeling, brightening and the like are achieved.
In order to improve the color development and the definition of the texture pattern, 74% -86% of transparent matte frit (3019 frit 62 +/-3%, 3082 frit 11 +/-2% and 3008 frit 7 +/-1%) is introduced by improving the proportion of the transparent matte frit in the formula of the protective glaze, the color development and the definition of the pattern are obviously improved by the higher proportion of the transparent matte frit, the obtained texture line boundary is clear at 400 resolution, and meanwhile, the concave-convex color of the glaze layer is gradually changed, fine and natural, is naturally formed, and is matched with the water retention and diffusion resistance of the overglaze, so that the groove of a test product is deeper, the concave depth of the texture can reach 60-75 microns, and the stereoscopic impression is stronger.
According to the invention, through the inkjet printer of 6-channel color ink and 6-channel functional ink, the effect of the protective glaze is matched, the effect and the precision of the engraving TEXTURE are further ensured by using the imported Sterculor 432TEXTURE engraving ink, the imported starlight 1024 nozzle, the resolution 400dpi and higher resolution, so that the delicate TEXTURE and TEXTURE which cannot be achieved by an engraving mould and other stripping products are achieved, and thus the high-simulation engraving silkete with a three-dimensional effect is formed on the surface of the brick.
The invention adopts an imported glaze spraying machine, when the pressure reaches more than 15bar, the protection glaze is fully and uniformly atomized, and each tile is 250 +/-5 g/m2The specific gravity is 1.40 plus or minus 0.02g/ml, the flow rate is 12-15 seconds, the total dry material is reduced by 45-50 percent compared with the common product, the usage amount of glaze is reduced, the cost is reduced, and the color development of the pattern is retained to the maximum extent. Meanwhile, a dust extractor is installed, and the atomized redundant glaze can be recycled, so that energy is saved, emission is reduced, and real environmental protection is achieved.
The description of the raw materials or terms in the present invention is as follows:
the 5009 frit is also known as KF-5009 frit: the matte glaze frit comprises the following chemical components in percentage by mass: 52% of silicon oxide, 12% of aluminum oxide, 3.5% of potassium oxide, 1.5% of sodium oxide, 9.5% of calcium oxide, 0.5% of magnesium oxide, 12% of barium oxide and 9% of zinc oxide; forming a main body of the glaze in the carved glaze, wherein the main body of the glaze is a main component of the carved glaze; produced by Foshanke Haiyinuo ceramics science and technology Co.
3019 frit also called KF-3019 frit: the matte glaze frit comprises the following chemical components in percentage by mass: 51.2% of silicon oxide, 10% of aluminum oxide, 4% of potassium oxide, 1.6% of sodium oxide, 13% of calcium oxide, 2.2% of magnesium oxide, 11% of barium oxide and 7% of zinc oxide; forming a main body of the glaze in the carved glaze, wherein the main body of the glaze is a main component of the carved glaze; produced by Foshanke Haiyinuo ceramics science and technology Co.
KF-3082 frit: the high-temperature matte frit is used for participating in the composition of the glaze in the carved glaze and is mainly used for adjusting the glossiness of the carved glaze; the chemical components by mass percentage are as follows: 61.5% of silicon oxide, 6.5% of aluminum oxide, 4.5% of potassium oxide, 1.2% of sodium oxide, 12% of calcium oxide, 1.5% of magnesium oxide, 3% of barium oxide, 6% of zinc oxide and 3.8% of boron oxide; produced by Foshanke Haiyinuo ceramics science and technology Co.
3008 frit also known as KF-3008 frit: the matte transparent frit participates in the composition of the glaze in the carved glaze, mainly plays a role in improving the carved transparency, and comprises the following chemical components in percentage by mass: 55.2% of silicon oxide, 14.9% of aluminum oxide, 4.7% of potassium oxide, 2.2% of sodium oxide, 5.6% of calcium oxide, 0.6% of magnesium oxide, 3% of barium oxide, 7% of zinc oxide and 6.8% of strontium oxide; produced by Foshanke Haiyinuo ceramics science and technology Co.
The airknife clay is also called kaolin for glaze, which means that the airknife kaolin for washing is used for glaze, participates in the main body of the glaze, adjusts the silicon-aluminum ratio, improves the suspension property of glaze slip, and is beneficial to glazing operation.
The yellow ink and the red ink are wrapped by yellow and zirconium silicate on the outer layer of the red pigment, and the coating is characterized by bright color development. The wrapping yellow ink is yellow ink, and can be made into 82012 product by Yangzi pigment Co. The package is red ink, which is 80016 from Yangzi pigment of Foshan.
The bright ink and the carved ink do not develop color, and have the effects of sinking, carving, brightening, matte and the like, and the bright ink can be a 3371 product which is coded by Foshansentite science and technology Limited. The refined carving ink can be selected from the product of the Simarouba chemical industry (Foshan) with the number of TRUCOLOR432 TEXTURE.
Compared with the prior art, the invention has the beneficial effect that
(1) According to the invention, 5% -9% of ball clay is introduced into the overglaze formula, and the water retention property of the ball clay is utilized to ensure that the lines printed by the fine engraving ink cannot be widened or diffused, so that the fineness and the distribution uniformity of the fine engraving texture lines are better realized, the fineness of the texture lines can reach 6 pixel units (namely 0.38mm) at least under the resolution of 400, and meanwhile, the rejection effect of the fine engraving ink on the protective glaze and the high-temperature melting and clouding effect of the fine engraving ink are utilized, so that the fine and natural pattern effect with the concave-convex effect, strong stereoscopic impression, high fineness of the texture lines, and fine and natural pattern effect is obtained, and the texture is further improved.
(2) According to the invention, by increasing the proportion of the transparent matte frit in the formula of the protective glaze and introducing 74% -86% of the transparent matte frit (3019 frit 62 +/-3%, 3082 frit 11 +/-2% and 3008 frit 7 +/-1%), the color development and definition of the pattern are obviously improved, the simulation degree is further improved, the obtained texture line boundary is clear and distinct under 400 resolution, the concave and convex colors of the glaze layer are gradually changed, fine and natural, and the texture groove is deeper and the texture concave depth can reach 60-75 um by matching with the water retention and diffusion resistance of the overglaze, so that the stereoscopic impression is stronger.
(3) In the glazed tile production method provided by the invention, the effect and precision of engraved texture are ensured, so that fine texture and texture which cannot be achieved by a fine engraving mould and other stripping products are achieved. Compared with the traditional method for obtaining the texture effect of the concave-convex pattern by adopting a green brick mould, the texture pattern obtained by the method is more exquisite, clear in texture, clear in color and lifelike.
Drawings
Fig. 1 is a schematic view of a glazed tile with a snake skin pattern obtained in example 1.
FIG. 2 is a schematic view of the texture of the snake skin-textured glazed tile obtained in example 1 under a light mirror.
FIG. 3 is a schematic view of the surface profile of the snakeskin furred glazed tile of example 1.
FIG. 4 is a schematic view of the glazed tile with feather grain pattern obtained in example 2.
FIG. 5 is a schematic view of the texture of the feather-grain glazed tile obtained in example 2 under a light mirror.
FIG. 6 is a schematic view of the surface profile of the feather-grained glazed tile obtained in example 2.
FIG. 7 is a schematic diagram of a glazed tile with a snake skin pattern obtained by the comparative example.
FIG. 8 is a schematic representation of the texture of a serpentine-furred glazed tile obtained from the comparative example under a light mirror.
FIG. 9 is a schematic representation of the surface profile of a serpentine-furred glazed tile obtained in a comparative example.
Detailed Description
For a better understanding of the present invention, the present invention will be further explained with reference to the drawings and examples, but the scope of the present invention as claimed is not limited to the scope of the examples described.
In the following examples and comparative examples, in step one, the raw material for the green brick was a general raw material for green brick, and the formulation thereof was mainly composed of potash feldspar, albite, talc, quartz, kaolin, mud, bentonite, alumina, etc., and the chemical composition thereof was silica 65 to 70 wt%, alumina 17 to 22 wt%, sodium oxide 1.5 to 3.5 wt%, potassium oxide 2.5 to 4 wt%, magnesium oxide 0.5 to 1.5 wt%, iron oxide 1 to 1.5 wt%, titanium oxide 0 to 0.2 wt%, and loss on ignition 4 to 6 wt%.
Example 1
A production method of an accurately carved snake skin-grain glazed tile comprises the following steps:
the first step is that the raw material formula of the green brick comprises: 68 wt% of silicon dioxide, 18.8 wt% of aluminum oxide, 2.2 wt% of sodium oxide, 3.9 wt% of potassium oxide, 0.8 wt% of magnesium oxide, 0.1 wt% of titanium oxide, 1.1 wt% of iron oxide and 5.1 wt% of loss on ignition. Preparing raw materials according to a raw material formula of a green brick, performing ball milling on the raw materials for 9 hours by a mixing wet method to obtain ceramic slurry, performing spray granulation on the ceramic slurry to obtain ceramic powder, and performing pressure forming on the powder under 45MPa to obtain a green brick of the ceramic.
And step two, putting the molded blank into a kiln for biscuiting, wherein the biscuiting temperature is 1070 ℃, and the firing period is 60 min.
Step three, spreading 6 on the ceramic blank by a glaze spraying device60g/m2A base coat, and then 440g/m of the base coat is spread on the base coat2And (7) overglaze. The ground glaze comprises the chemical components of 5.2 wt% of aluminum oxide, 60 wt% of silicon dioxide, 0.1 wt% of ferric oxide, 18.3 wt% of calcium oxide, 1.4 wt% of magnesium oxide, 2.3 wt% of potassium oxide, 0.9 wt% of sodium oxide, 9.5 wt% of titanium dioxide, 0.8 wt% of zinc oxide, 1 wt% of barium oxide and 0.5 wt% of loss on ignition;
the formula of the overglaze comprises 5009 frit 49%, zirconium silicate 13%, calcined alumina 17%, wollastonite powder 5%, calcined talcum powder 3%, calcined kaolin 2%, ball clay powder 9% and air knife soil 2%; the overglaze comprises 31% of aluminum oxide, 40% of silicon dioxide, 0.2% of ferric oxide, 8.5% of calcium oxide, 2.5% of magnesium oxide, 2% of potassium oxide, 1.2% of sodium oxide, 6.3% of zinc oxide, 7% of boron oxide and 0.5% of loss on ignition. By introducing ball clay with the content of 9%, the lines printed by the later-stage engraving ink are not easy to diffuse on the overglaze and cannot be widened by utilizing the water retention property of the ball clay, so that the size and the distribution uniformity of the grains are ensured.
And step four, drying before ink jetting, wherein the drying temperature is 220 ℃, and the drying period is 90 s.
Step five, sequentially printing color ink and functional ink on the overglaze through a digital ink-jet printer (with an inlet starlight 1024 nozzle and a resolution of 400dpi) according to a set snakeskin texture pattern, wherein the color ink comprises blue ink, brown ink, wrapped yellow ink, wrapped red ink, black ink and green ink; the functional ink comprises bright ink and carved ink; the proportion of the color ink glazed tile is prepared according to the color requirement of the layout; the functional ink is prepared according to the finishing impression and the light effect (thickness, depth and brightness) of the glazed tile, and different types of color ink and functional ink are related in the prior art according to different product requirements. Thereby the pattern position of spout seal having the finishing impression ink can produce the groove form glaze morphology of repulsion action obtaining certain degree of depth to the protection glaze of later stage cloth application, simultaneously, at the glaze in later stage burns the in-process, the high temperature that the finishing impression ink has melts turbid effect and further the slot that forms when implementing the protection glaze further sinks to obtain having unsmooth effect, the fine and smooth nature of texture, the clear even finishing impression snakeskin line of color and luster.
And step six, drying after ink jetting, wherein the drying temperature is 220 ℃, and the drying period is 120 s.
And step seven, distributing and applying 50g of protective glaze on the ink-jet pattern according to the ceramic tile glazing process. The formula of the protective glaze is 86% of transparent matte frit (wherein 3019 frit 65%, 3082 frit 13%, 3008 frit 8%), zinc oxide 8%, calcined kaolin 1%, air knife soil 3% and ball clay 2%; the chemical components of the protective glaze comprise 14.0% of aluminum oxide, 61.0% of silicon dioxide, 1.5% of potassium oxide, 3.0% of sodium oxide, 5.0% of calcium oxide, 1.0% of magnesium oxide, 8.0% of zinc oxide, 1.2% of boron oxide, 4.5% of barium oxide, 1.0% of strontium oxide and 0.5% of loss on ignition; by introducing 86% of transparent matte frits (namely 3019 frits 65%, 3082 frits 13% and 3008 frits 8%) into the protective glaze, the color development and definition of patterns are obviously improved, the simulation degree is further improved, the concave-convex color of the glaze layer is gradually changed, fine and natural, and the concave-convex color is naturally natural and is matched with the water retention and diffusion prevention performance of the overglaze, so that the texture grooves are deeper, and the texture concave depth can reach 75um, so that the stereoscopic impression is stronger.
And step eight, putting the ceramic biscuit coated with the protective glaze into a kiln for calcination, wherein the calcination temperature is 1040 ℃, the calcination period is 65min, and obtaining the glazed tile with the refined carving snake skin texture effect through calcination and edge grinding.
The product of the embodiment is a glazed tile with the effect of carved snakeskin lines, 9% of ball clay is introduced into a glaze formula, 86% of transparent matte frit is introduced into a protective glaze formula, the fineness and the uniformity of the snakeskin lines are ensured by utilizing the water retention property of the ball clay, the transparency of a pattern is improved by adding the transparent matte frit, the softness of the glaze is increased while extinction is realized, the color development and the definition of the pattern are obviously improved, and the simulation degree is further improved. Fig. 1 is the local schematic diagram of this embodiment of finishing impression snakeskin grain glazed tile who shoots, can discover from the picture that the snakeskin texture is fine and smooth even, and the pattern definition is high, has good unsmooth effect, and the pattern third dimension is strong, the effect is lifelike simultaneously, has higher fidelity.
Fig. 2 is a light microscope image of the texture of the carved snakeskin-grain glazed tile in this embodiment, the precision of the texture of the snakeskin is measured by an optical microscope (the optical microscope is a product of Olympus japan, the model is SZX10, the main function is to obtain a microstructure by magnifying imaging, and the fineness of the texture can be further understood by observing the microstructure), it is found that the fineness of the line of the texture can reach 6 pixel units (i.e., 0.38mm) at the minimum under 400 resolution, and the boundary of the obtained texture is clearly distinguished under 400 resolution, while the fineness of the texture of the glazed tile with a concave-convex texture special effect pattern obtained under the general prior art can only reach 8 pixel units (i.e., 0.508mm) at the minimum under 400 resolution, which is obviously lower than the fineness of the texture of the product of this embodiment, it can be seen that the fineness of the texture is significantly improved while the definition of the texture pattern is ensured, the decorative quality of the glazed tile is improved powerfully.
Fig. 3 is a schematic view of the surface profile of the carved snakeskin-textured glazed tile in this embodiment (fig. 3 is obtained by analyzing a surface profiler, a manufacturer is japan san feng, the model is SJ-400, and the depth of concavity of texture can be known and analyzed more visually through the surface profile), the schematic view more visually represents the fineness of the texture and the good sense of concavity and convexity, and meanwhile, the depth of concavity can be obtained by analyzing about 75um, while the depth of concavity and convexity of a glazed tile with a special effect pattern of concavo-convex texture obtained under the general prior art is about 50um, so that the product under this embodiment can ensure the depth of concavity of deeper texture, thereby showing the sense of concavity and convexity of better texture.
Example 2
A production method of a carved feather grain glazed tile comprises the following steps:
the first step is that the raw material formula of the green brick comprises: 68.0 wt% of silicon dioxide, 18.8 wt% of aluminum oxide, 2.2 wt% of sodium oxide, 3.9 wt% of potassium oxide, 0.8 wt% of magnesium oxide, 0.1 wt% of titanium oxide, 1.1 wt% of iron oxide and 5.1 wt% of loss on ignition. After the raw materials are prepared according to the composition, the raw materials are subjected to ball milling for 9 hours by a mixing wet method to obtain ceramic slurry, the ceramic slurry is subjected to spray granulation to obtain ceramic powder, and the powder is subjected to pressure forming under 45MPa to obtain a ceramic brick blank.
And step two, putting the molded blank into a kiln for biscuiting, wherein the biscuiting temperature is 1080 ℃, and the firing period is 55 min.
Step three, distributing 620g/m of glaze on the ceramic blank body through a glaze spraying device2A ground coat, and then 430g/m of the ground coat is spread on the ground coat2And (7) overglaze. The ground glaze comprises the chemical components of 5.3 wt% of aluminum oxide, 61 wt% of silicon dioxide, 0.1 wt% of ferric oxide, 18.5 wt% of calcium oxide, 1.3 wt% of magnesium oxide, 2.5 wt% of potassium oxide, 1.0 wt% of sodium oxide, 10.0 wt% of titanium dioxide, 1.0 wt% of zinc oxide, 1.0 wt% of barium oxide and 0.5 wt% of loss due to ignition.
The overglaze formula comprises 5009 frit 51%, zirconium silicate 14%, calcined alumina 15%, wollastonite powder 6%, calcined talcum powder 4%, calcined kaolin 2%, ball clay powder 5% and air knife soil 3%; the overglaze comprises the chemical components of 28 wt% of aluminum oxide, 44 wt% of silicon dioxide, 0.1 wt% of ferric oxide, 8.5 wt% of calcium oxide, 2 wt% of magnesium oxide, 1.5 wt% of potassium oxide, 1 wt% of sodium oxide, 6.5 wt% of zinc oxide, 7.5 wt% of boron oxide and 0.5 wt% of loss on ignition; by introducing ball clay with 5% of content and utilizing the water retention property of the ball clay, lines printed by the later-stage engraving ink are not easy to diffuse on the overglaze, the lines cannot be widened, and the size and the distribution uniformity of the grains are ensured.
And step four, drying before ink jetting, wherein the drying temperature is 215 ℃, and the drying period is 100 s.
And fifthly, according to the set feather texture pattern, sequentially printing color ink and functional ink on the overglaze through a digital ink-jet printer, wherein the color ink comprises blue ink, brown ink, wrapped yellow ink, wrapped red ink, black ink and green ink, and the functional ink comprises bright ink and carved ink. The pattern part sprayed with the carved ink can repel the protective glaze distributed in the later period to obtain a groove-shaped glaze surface form with a certain depth, and meanwhile, in the glaze firing process in the later period, the carved ink has a high-temperature melting and clouding effect to further enable the groove formed in the protective glaze application to further sink, so that the carved feather lines with a concave-convex effect, fine and natural texture and clear and uniform color are obtained.
And step six, drying after ink jetting, wherein the drying temperature is 215 ℃, and the drying period is 130 s.
And step seven, distributing 45g of protective glaze on the ink-jet pattern according to a known ceramic tile glazing process. The formula of the protective glaze is 74 percent of transparent matte frits (3019 frits 59 percent, 3082 frits 9 percent and 3008 frits 6 percent), 12 percent of zinc oxide, 2.5 percent of calcined kaolin, 8 percent of air knife soil and 3.5 percent of ball clay; the chemical components of the protective glaze comprise 15.0 percent of aluminum oxide, 57.0 percent of silicon dioxide, 1.5 percent of potassium oxide, 3.0 percent of sodium oxide, 7.0 percent of calcium oxide, 1.0 percent of magnesium oxide, 6.0 percent of zinc oxide, 1.2 percent of boron oxide, 4.5 percent of barium oxide, 1.0 percent of strontium oxide and 0.5 percent of loss on ignition. By introducing 74% of transparent matte frits (namely 3019 frits 59%, 3082 frits 11% and 3008 frits 6%) into the protective glaze, the color development and definition of patterns are obviously improved, the simulation degree is further improved, the concave-convex color of the glaze layer is gradually changed, fine and natural, and the concave-convex color is naturally natural and is matched with the water retention and diffusion resistance of the overglaze, so that the texture grooves are deeper, the texture concave depth can reach 60um, and the stereoscopic impression is stronger.
And step eight, putting the ceramic biscuit coated with the protective glaze into a kiln for calcination, wherein the calcination temperature is 1050 ℃, the calcination period is 55min, and obtaining the glazed tile with the effect of finely carving the feather grains after calcination and edging.
The product of the embodiment is a glazed tile with a feather grain effect, 5% of ball clay is introduced into a glaze formula, 74% of transparent matte frit is introduced into a protective glaze formula, the fineness and uniformity of the snake skin grains are guaranteed by utilizing the water retention property of the ball clay, the transparency of a pattern is improved by adding the transparent matte frit, the softness of the glaze is increased while extinction is carried out, the color development and definition of the pattern are obviously improved, and the simulation degree is further improved. Fig. 4 is a schematic view of a part of the feather-grain glazed tile in the embodiment, and it can be found from the figure that feather grains are fine and uniform, the pattern definition is high, a good concave-convex effect is achieved, and meanwhile, the pattern has a strong stereoscopic impression, a vivid effect and a high simulation degree. Fig. 5 is a light microscope image of the texture of the feather-grain glazed tile in the embodiment, the precision of the feather texture is measured through an optical microscope, it is found that the minimum precision of the texture can be controlled to reach 6 pixel units (i.e. 0.38mm) under the resolution of 400, the boundary of the obtained texture line is clear under the resolution of 400, and the fineness of the texture is higher than that of the texture line (0.508nm) in the general prior art, so that the fineness of the texture is better improved and the good pattern definition is ensured. Fig. 6 is a schematic surface profile obtained by photographing with a surface profiler, the schematic surface profile of the precisely-carved feather glazed tile in the present embodiment more intuitively shows the fineness of the texture and the good sense of concavity and convexity, and the depth of concavity is about 60um obtained by analyzing and measuring the surface profile curve, so as to ensure the depth of concavity of deeper texture.
Example 3
A production method of an accurately carved snake skin-grain glazed tile comprises the following steps:
the first step is that the raw material formula of the green brick comprises: 68.0 wt% of silicon dioxide, 18.8 wt% of aluminum oxide, 2.2 wt% of sodium oxide, 3.9 wt% of potassium oxide, 0.8 wt% of magnesium oxide, 0.1 wt% of titanium oxide, 1.1 wt% of iron oxide and 5.1 wt% of loss on ignition. After the raw materials are prepared according to the composition, the raw materials are subjected to ball milling for 9 hours by a mixing wet method to obtain ceramic slurry, the ceramic slurry is subjected to spray granulation to obtain ceramic powder, and the powder is subjected to pressure forming under 45MPa to obtain a ceramic brick blank.
And step two, putting the molded blank into a kiln for biscuiting, wherein the biscuiting temperature is 1080 ℃, and the firing period is 55 min.
Step three, distributing 620g/m of glaze on the ceramic blank body through a glaze spraying device2A ground coat, and then 430g/m of the ground coat is spread on the ground coat2And (7) overglaze. The ground glaze comprises the chemical components of 5.3 wt% of aluminum oxide, 61 wt% of silicon dioxide, 0.1 wt% of ferric oxide, 18.5 wt% of calcium oxide, 1.3 wt% of magnesium oxide, 2.5 wt% of potassium oxide, 1.0 wt% of sodium oxide, 10.0 wt% of titanium dioxide, 1.0 wt% of zinc oxide, 1.0 wt% of barium oxide and 0.5 wt% of loss due to ignition.
The formula of the overglaze comprises 50% of 5009 clinker, 14% of zirconium silicate, 14% of calcined alumina, 6% of wollastonite powder, 4% of calcined talcum powder, 2% of calcined kaolin, 7% of ball clay powder and 3% of air knife soil; the overglaze comprises the chemical components of 30 wt% of aluminum oxide, 42 wt% of silicon dioxide, 0.1 wt% of ferric oxide, 8.5 wt% of calcium oxide, 2 wt% of magnesium oxide, 1.5 wt% of potassium oxide, 1 wt% of sodium oxide, 6.5 wt% of zinc oxide, 7.5 wt% of boron oxide and 0.5 wt% of loss on ignition; by introducing ball clay with the content of 7%, the lines printed by the later-stage engraving ink are not easy to diffuse on the overglaze and cannot be widened by utilizing the water retention property of the ball clay, so that the size and the distribution uniformity of the grains are ensured.
And step four, drying before ink jetting, wherein the drying temperature is 215 ℃, and the drying period is 100 s.
And fifthly, according to the set snakeskin texture pattern, sequentially printing color ink and functional ink on the overglaze through a digital ink-jet printer, wherein the color ink comprises blue ink, brown ink, package yellow ink, package red ink, black ink and green ink, and the functional ink comprises bright ink and carved ink. The pattern part sprayed with the carved ink can repel the protective glaze applied in the later period to obtain a groove-shaped glaze surface form with a certain depth, and meanwhile, in the glaze firing process in the later period, the carved ink has a high-temperature melting and clouding effect to further enable the groove formed in the process of applying the protective glaze to further sink, so that the carved snakeskin grain with a concave-convex effect, fine and natural texture and clear and uniform color is obtained.
And step six, drying after ink jetting, wherein the drying temperature is 215 ℃, and the drying period is 130 s.
And step seven, distributing 45g of protective glaze on the ink-jet pattern according to a known ceramic tile glazing process. The formula of the protective glaze comprises 80% of transparent matte frits (3019 frits 62%, 3082 frits 10%, 3008 frits 8%), 9% of zinc oxide, 2% of calcined kaolin, 6% of air-knife soil and 3% of ball clay; the chemical components of the protective glaze comprise 14.0 percent of aluminum oxide, 59.0 percent of silicon dioxide, 1.5 percent of potassium oxide, 3.0 percent of sodium oxide, 6.0 percent of calcium oxide, 1.0 percent of magnesium oxide, 7.0 percent of zinc oxide, 1.2 percent of boron oxide, 3.5 percent of barium oxide, 1.0 percent of strontium oxide and 0.5 percent of loss on ignition. By introducing 80% of transparent matte frits (namely 3019 frits 62%, 3082 frits 10% and 3008 frits 8%) into the protective glaze, the color development and definition of patterns are obviously improved, the simulation degree is further improved, the concave-convex color of the glaze layer is gradually changed, fine and natural, and the concave-convex color is naturally natural and is matched with the water retention and diffusion resistance of the overglaze, so that the texture grooves are deeper, the texture concave depth can reach 65um, and the stereoscopic impression is stronger.
And step eight, putting the ceramic biscuit coated with the protective glaze into a kiln for calcination, wherein the calcination temperature is 1050 ℃, the calcination period is 55min, and obtaining the glazed tile with the refined carving snake skin texture effect through calcination and edge grinding.
The product of the embodiment is a glazed tile with a snakeskin grain effect, 7% of ball clay is introduced into a glaze formula, 80% of transparent matte frit is introduced into a protective glaze formula, the fineness and the uniformity of the snakeskin grains are ensured by utilizing the water retention property of the ball clay, the transparency of a pattern is improved by adding the transparent matte frit, the softness of the glaze is increased while extinction is realized, the color development and the definition of the pattern are obviously improved, and the simulation degree is further improved. The snakeskin grain glazed tile has the advantages that the minimum precision of the texture can be controlled to be 6 pixel units (namely 0.38mm) under the resolution ratio of 400, the boundary of the obtained texture line is clear under the resolution ratio of 400, and the texture fineness is higher than that of the texture line (0.508nm) in the prior art, so that the fineness of the texture is improved better, the good pattern definition is guaranteed, meanwhile, the depth of the texture concave is about 65 microns under the embodiment obtained through the analysis of a surface profiler, and the snakeskin grain glazed tile has better texture concave-convex feeling.
The overglaze raw material formula comprises: 5009 percent of clinker 49 +/-3 percent, 14 +/-2 percent of zirconium silicate, 15 +/-2 percent of calcined alumina, 5 +/-1 percent of wollastonite powder, 4 +/-0.5 percent of calcined talcum powder, 2 +/-0.2 percent of calcined kaolin, 7 +/-2 percent of ball clay powder and 3 +/-1 percent of air-knife soil; the protective glaze comprises the following raw materials in formula: 74-86% of transparent matte frit (3019 frit 62 + -3%, 3082 frit 11 + -2%, 3008 frit 7 + -1%), zinc oxide 6 + -2%, calcined kaolin 2 + -0.5%, air-knife soil 6 + -1%, and ball soil 3 + -0.5%.
Comparative example
A production method of snakeskin grain glazed tile comprises the following steps:
the first step is that the raw material formula of the green brick comprises: 68 wt% of silicon dioxide, 18.8 wt% of aluminum oxide, 2.2 wt% of sodium oxide, 3.9 wt% of potassium oxide, 0.8 wt% of magnesium oxide, 0.1 wt% of titanium oxide, 1.1 wt% of iron oxide and 5.1 wt% of loss on ignition. After the raw materials are prepared according to the composition, the raw materials are subjected to ball milling for 9 hours by a mixing wet method to obtain ceramic slurry, the ceramic slurry is subjected to spray granulation to obtain ceramic powder, and the powder is subjected to pressure forming under 45MPa to obtain a ceramic brick blank.
And step two, putting the molded blank into a kiln for biscuiting, wherein the biscuiting temperature is 1070 ℃, and the firing period is 60 min.
Step three, distributing 620g/m of glaze on the ceramic blank body through a glaze spraying device2A ground coat, and then 430g/m of the ground coat is spread on the ground coat2And (7) overglaze. The ground glaze comprises the chemical components of 5.2 wt% of aluminum oxide, 60 wt% of silicon dioxide, 0.1 wt% of ferric oxide, 18.3 wt% of calcium oxide, 1.4 wt% of magnesium oxide, 2.3 wt% of potassium oxide, 0.9 wt% of sodium oxide, 9.5 wt% of titanium dioxide, 0.8 wt% of zinc oxide, 1 wt% of barium oxide and 0.5 wt% of loss on ignition;
the overglaze formula comprises 5009 frit 51%, zirconium silicate 14%, calcined alumina 15%, wollastonite powder 6%, calcined talcum powder 4%, calcined kaolin 2%, ball clay powder 4% and air knife soil 3%; the overglaze comprises 27 wt% of aluminum oxide, 45 wt% of silicon dioxide, 0.1 wt% of ferric oxide, 8.5 wt% of calcium oxide, 2 wt% of magnesium oxide, 1.5 wt% of potassium oxide, 1 wt% of sodium oxide, 6.5 wt% of zinc oxide, 7.5 wt% of boron oxide and 0.5 wt% of loss due to ignition;
and step four, drying before ink jetting, wherein the drying temperature is 220 ℃, and the drying period is 90 s.
And fifthly, according to the set snakeskin texture pattern, sequentially printing color ink and functional ink on the overglaze through a digital ink-jet printer, wherein the color ink comprises blue ink, brown ink, package yellow ink, package red ink, black ink and green ink, and the functional ink comprises bright ink and carved ink. Thereby the pattern position that the jet printing has the cnc engraving ink can produce the slot form glaze morphology of repulsion action certain degree of depth to the protection glaze of later stage cloth application, simultaneously, at the glaze firing in-process in later stage, the high temperature that the cnc engraving ink has melts turbid effect and further makes the slot that forms when applying the protection glaze further sink to obtain and have unsmooth effect, the fine and smooth nature of texture, the clear even cnc engraving snakeskin line of color and luster.
And step six, drying after ink jetting, wherein the drying temperature is 220 ℃, and the drying period is 120 s.
And step seven, distributing 45g of protective glaze on the ink-jet pattern according to a known ceramic tile glazing process. The formula of the protective glaze is 73 percent of transparent matte frits (3019 frits 58 percent, 3082 frits 9 percent and 3008 frits 6 percent), 12 percent of zinc oxide, 3.5 percent of calcined kaolin, 8 percent of air knife soil and 3.5 percent of ball clay; the chemical components of the protective glaze comprise 16.0 percent of aluminum oxide, 56.0 percent of silicon dioxide, 1.5 percent of potassium oxide, 3.0 percent of sodium oxide, 8.0 percent of calcium oxide, 1.0 percent of magnesium oxide, 5.0 percent of zinc oxide, 1.2 percent of boron oxide, 4.5 percent of barium oxide, 1.0 percent of strontium oxide and 0.5 percent of loss on ignition;
and step eight, putting the ceramic biscuit coated with the protective glaze into a kiln for calcination, wherein the calcination temperature is 1040 ℃, the calcination period is 65min, and obtaining the glazed tile with the refined carving snake skin texture effect through calcination and edge grinding.
The product of the comparative example is a glazed tile with the effect of carved snakeskin lines, which is different from the embodiment 2 in that in the comparative example, 4% of ball clay proportion is introduced into a glaze formula, and 73% of transparent matte frit proportion is introduced into a protective glaze formula, and due to the reduction of the ball clay content, the water retention of the glaze is reduced, so that lines printed by the carved ink are diffused, and therefore the carved snakeskin lines obtained by the comparative example have poor effect, the fineness and the uniformity of the grains are low, and the fineness of the grains can be controlled to be 9 pixel units (namely 0.57mm) under the resolution of 400. And the reduction of the content of the transparent matte frit reduces the transparency of the pattern and the softness of the glaze surface, so that the color development of the pattern is not clear, and the boundary of the snakeskin texture is fuzzy under the resolution of 400. Meanwhile, the glaze surface has weak concave-convex property, weak stereoscopic impression and low simulation degree. Fig. 7 is a schematic view of a partial carved snakeskin grain glazed tile in the comparative example, and it can be seen from the figure that fig. 1 in comparative example 1 shows that the snakeskin grain in the comparative example has low precision, fuzzy patterns, poor stereoscopic impression and low simulation degree. Fig. 8 is a light mirror image of a refined snakeskin texture under a comparative example, and compared with fig. 2 in example 1, it can be clearly found that the snakeskin texture under the comparative example has blurred edges and unclear line boundaries under 400 resolution. Fig. 9 is a schematic view of the surface profile of the snakeskin glazed tile under the comparative example, and compared with the schematic surface profiles of examples 1 and 2, it can be found more intuitively that the texture is poor in concave-convex feeling, the depth of the texture is only 53um, and the fineness and uniformity of the texture are low.
It should be noted that, too high content of ball clay affects the performance of the glaze slip, the viscosity of the glaze slip becomes high, bubbles in the glaze slip are not easy to release, pinholes or pits can be formed after glaze spraying, and the ball clay is used as plastic clay, and too much (10%) content of ball clay causes large shrinkage of glaze during drying, so that cracks are generated on the glaze, that is, when the content of ball clay is more than 9%, a series of defects can be caused. And the ball clay is more expensive than the air knife clay used conventionally, so that the effect of the finished glazed tile when the ball clay content is more than 9 percent is not further researched in consideration of the cost. But example 1 has proved to have a good effect when the ball content is 9% by mass.
In the second step of the above embodiment, because the overglaze formula contains 5% to 9% of ball clay, and the water retention of the ball clay ensures that the lines printed by the fine engraving ink cannot be widened or diffused, the fineness and the distribution uniformity of the fine engraving texture lines are better realized, and the fineness can reach 6 pixel units (i.e. 0.38mm) at the minimum under the resolution of 400.
In the fourth step of the above embodiment, for the textures of the snakeskin and the feather, the usage ratio of the inks is determined according to the respective pattern effects, and the texture pattern is free texture of the document, that is, the pattern of the required texture is input in a computer, and then the corresponding pattern is printed by a digital ink-jet printer. The combination of different inks embodies the multidimensional three-dimensional printing effect, and the combination of high simulation is achieved, wherein the functional ink preferably uses imported Sterculor 432TEXTURE carved ink, the water repellency of the carved ink enables the carved ink to rapidly discharge a water-based glaze layer after spraying protective glaze, so as to form a fine carved effect, color ink develops on the surface of the overglaze, the color ink generates physical and chemical changes through high-temperature firing of a kiln, the concave-convex effects of glaze throwing and protective glaze are not changed, the colored glaze belongs to in-glaze color development, the digital ink-jet printer uses an imported star 1024 nozzle, the resolution is 400dpi, and the higher resolution further ensures the effect and the precision of the carved TEXTURE, so that the delicate TEXTURE and the TEXTURE which cannot be achieved by carved molds and other stripped products are achieved; in addition, the high-temperature melting and clouding effect of the carved ink enables the groove formed in glazing to further sink, so that the carved line has the decoration aesthetic feeling like natural cracks, can react with the overglaze to form metal luster, and forms a crystal line on the carved line, thereby having the effects of sinking and stripping, brightening and the like.
In the sixth step of the above embodiment, the usage amount of the dry protective glaze is reduced by 45% to 50% compared with that of the common protective glaze product, which not only reduces the usage amount of the glaze material and the cost, but also retains the color development of the pattern to the greatest extent. The 74% -86% of the transparent matte frits (3019 frits 62 +/-3%, 3082 frits 11 +/-2% and 3008 frits 7 +/-1%) in the protective glaze component ensures higher definition of patterns, the obtained grain line boundaries are clear under 400 resolution, and meanwhile, the concave-convex color of the glaze layer gradually changes, is fine, natural and natural, is matched with the water retention and diffusion prevention performance of the surface glaze, so that the groove of a test product is deeper, and the concave depth can reach 60-75 microns, and the stereoscopic impression is stronger.
As can be seen from the texture schematic diagram of the glazed tile obtained in the following example, compared with the carved snakeskin texture obtained in the comparative example, the carved snakeskin texture obtained in the example 1 and the carved feather texture obtained in the example 2 have higher proportions of ball and clay introduced into the glaze under the condition that other conditions are not changed, and higher proportions of transparent matte frit introduced into the protective glaze, so that the fineness, the concave-convex feeling and the definition of the texture pattern of the obtained texture pattern are greatly improved, the minimum precision of the texture can be controlled to be 6 pixel units (i.e., 0.38mm) under the resolution of 400, the boundary of the obtained texture line is clearly distinguished under the resolution of 400, and the depth of the texture concave can reach 60-75 um. The difference in this effect is due to the increased proportion of ball clay to clear matte frit. The fineness and the uniformity of snakeskin grains are guaranteed by the water-retaining property of ball clay, the transparency of the pattern is improved by adding the transparent matte frit, the softness of the glaze surface is increased while extinction is realized, the color development and the definition of the pattern are obviously improved, the simulation degree is further improved, and meanwhile, the water-retaining diffusion-preventing property of the glaze surface is matched, so that the grain grooves are deeper, and the stereoscopic impression is stronger.
The present invention has been described in connection with specific embodiments, which are set forth merely to illustrate the principles of the invention and are not to be construed as limiting the scope of the invention in any way. Based on the explanations herein, those skilled in the art will be able to conceive of other embodiments of the present invention without inventive effort, which would fall within the scope of the present invention.
Claims (10)
1. A carving mercerized glazed tile is prepared by biscuit firing a porcelain tile blank, then applying a ground glaze, then applying a surface glaze on the ground glaze, then drying, printing color ink and functional ink by a digital ink-jet printer, then drying, spraying protective glaze and firing; the method is characterized in that: the overglaze comprises the following raw materials in percentage by mass: 5009 clinker 49 + -3%, zirconium silicate 14 + -2%, calcined alumina 15 + -2%, wollastonite powder 5 + -1%, calcined talcum powder 4 + -1%, calcined kaolin 2 + -0.2%, ball clay powder 7 + -2% and air knife soil 3 + -1%; the protective glaze comprises the following raw materials in formula: 74-86% of transparent matte frit, 10 +/-2% of zinc oxide, 2 +/-0.5% of calcined kaolin, 6 +/-2% of air knife soil and 3 +/-0.5% of ball clay.
2. The engraved mercerized glazed tile according to claim 1, wherein the depth of texture concave of the engraved mercerized glazed tile is 60-75 um, the fineness of the texture is as small as 6 pixel units under 400 resolution, and the boundary of the texture line is clear under 400 resolution.
3. The engraved mercerized glazed tile of claim 1, wherein the transparent matte frit consists of 3019 frit 62 ± 3%, 3082 frit 11 ± 2%, and 3008 frit 7 ± 1% by mass.
4. The engraved mercerized glazed tile according to claim 1, wherein the ground glaze comprises the following chemical components in percentage by mass: 5.3 +/-0.3 percent of aluminum oxide, 61.0 +/-1 percent of silicon dioxide, 0.2 +/-0.01 percent of ferric oxide, 18.5 +/-0.2 percent of calcium oxide, 1.3 +/-0.2 percent of magnesium oxide, 2.5 +/-0.2 percent of potassium oxide, 1.0 +/-0.1 percent of sodium oxide, 10.0 +/-0.5 percent of titanium dioxide, 1.0 +/-0.2 percent of zinc oxide, 1.0 +/-0.2 percent of barium oxide and 0.5 +/-0.2 percent of loss on ignition.
5. The engraved mercerized glazed tile according to claim 1, wherein the glazed tile is prepared from the following materials in percentage by mass, the chemical components of the engraving and milling ink comprise, by mass, 56.0 +/-2% of ignition loss, 3.5 +/-0.2% of aluminum oxide, 25.0 +/-0.5% of silicon dioxide, 0.1 +/-0.01% of ferric oxide, 8.0 +/-0.2% of calcium oxide, 1.5 +/-0.2% of potassium oxide, 0.08 +/-0.02% of sodium oxide, 0.05 +/-0.01% of titanium dioxide, 0.05 +/-0.01% of phosphorus pentoxide, 5.0 +/-0.2% of zinc oxide, 0.01 +/-0.002% of lead oxide, 0.01 +/-0.002% of sulfur trioxide, 0.05 +/-0.01% of boron trioxide, 0.05 +/-0.01% of fluorine, 0.01 +/-0.002% of lithium oxide, 0.01 +/-0.002% of strontium oxide, 0.01 +/-0.002% of manganese oxide, 0.01 +/-0.002% of cadmium oxide, 0.01 +/-0.002% of chromium trioxide, 0.002%, 0.01 +/-0.002% of nickel oxide, 0.002% of cobalt oxide, 0.002% of cesium oxide, 0.01 +/-0.002% of cobalt oxide, 0.01 +/-0.002% of cesium oxide.
6. The engraved mercerized glazed tile according to claim 1, wherein the protective glaze comprises the following chemical components in percentage by mass: 15.0 +/-0.5% of aluminum oxide, 59.0 +/-2% of silicon dioxide, 1.5 +/-0.2% of potassium oxide, 3.0 +/-0.2% of sodium oxide, 6.0 +/-1% of calcium oxide, 1.0 +/-0.2% of magnesium oxide, 7.0 +/-1% of zinc oxide, 1.2 +/-0.2% of boron oxide, 4.5 +/-0.2% of barium oxide, 1.0 +/-0.2% of strontium oxide and 0.5 +/-0.2% of loss of ignition.
7. The engraved mercerized glazed tile according to claim 1, wherein the chemical components of the glaze comprise, by mass: 29 plus or minus 2 percent of aluminum oxide, 42 plus or minus 2 percent of silicon dioxide, 0.2 plus or minus 0.01 percent of ferric oxide, 8 plus or minus 0.5 percent of calcium oxide, 2 plus or minus 0.5 percent of magnesium oxide, 2 plus or minus 0.2 percent of potassium oxide, 1.0 plus or minus 0.1 percent of sodium oxide, 6.5 plus or minus 0.2 percent of zinc oxide, 7 plus or minus 0.2 percent of boron oxide and 0.5 plus or minus 0.2 percent of loss on ignition.
8. The engraved mercerized glazed tile of claim 1, wherein said color inks include blue, brown, encapsulated yellow, encapsulated red, black and green inks; the functional ink comprises one or two of bright ink and carved ink.
9. The method for producing the openworked mercerized glazed tile as claimed in any one of claims 1 to 8, which is characterized by comprising the following steps:
1) pressing and molding the green body, and biscuiting the green body of the porcelain brick;
2) overglaze and ground glaze: distributing a base glaze on the ceramic tile blank through a glaze pouring device, and distributing a cover glaze on the base glaze;
3) drying before ink jetting;
4) ink-jet printing: printing color ink and functional ink in sequence by adopting a digital ink-jet printer;
5) drying after ink jetting;
6) spraying protective glaze by a glaze spraying machine, wherein the spraying amount of the protective glaze is 250 +/-5 g/m2；
7) And firing to obtain the glazed tile with the engraved mercerizing effect.
10. The method for producing the engraved mercerized glazed tile according to claim 9, which is characterized in that:
in the step 1), the biscuit firing temperature is 1075 +/-5 ℃, and the firing period is 55 +/-5 min;
in the step 2), 610 +/-10 g/m of glaze is spread on the ceramic tile blank body through a glaze spraying device2A base coat, and then 440 +/-10 g/m of the base coat is spread on the base coat2Overglaze
In the step 3), the drying temperature is 220 +/-5 ℃, and the drying period is 90 +/-10 s;
in the step 4), the digital ink-jet printer is a novel 12-channel ink-jet printer, wherein 6 channels are color ink channels and are respectively provided with blue ink, brown ink, package yellow ink, package red ink, black ink and green ink; in addition, the 6 channels are functional ink channels, wherein the 2 channels are respectively provided with bright ink and carved ink;
in the step 5), the drying temperature is 220 +/-5 ℃, and the drying period is 120 +/-10 s;
in the step 6), spraying protective glaze by using an imported AIR POWER glaze spraying machine, wherein the spraying amount of the protective glaze is 250 +/-5 g/m when the pressure reaches more than 15bar2The specific gravity is 1.40 +/-0.03 g/ml, and the spraying flow rate is 12-15 seconds; in the step 7), the sintering temperature is 1045 +/-5 ℃, and the sintering period is 60 +/-5 min.
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