CN113896569A - 具有多色透光立体效果陶瓷岩板及其制造方法 - Google Patents

具有多色透光立体效果陶瓷岩板及其制造方法 Download PDF

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Publication number
CN113896569A
CN113896569A CN202111127397.7A CN202111127397A CN113896569A CN 113896569 A CN113896569 A CN 113896569A CN 202111127397 A CN202111127397 A CN 202111127397A CN 113896569 A CN113896569 A CN 113896569A
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glaze
transmitting
powder
green
spraying
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CN113896569B (zh
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陈伟胤
王瑞峰
朱立洪
赵阳
杨庆霞
杨权
刘君
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Guangdong Dongwei New Material Co ltd
Jiangxi Hemei Ceramics Co Ltd
Jiangxi Wonderful Ceramics Co Ltd
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Guangdong Dongwei New Material Co ltd
Jiangxi Hemei Ceramics Co Ltd
Jiangxi Wonderful Ceramics Co Ltd
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Abstract

本发明涉及一种具有多色透光立体效果陶瓷岩板及其制造方法。制造方法：⑴多种彩色透光配方制备；⑵坯体根据设置图案布料，并压制成型；⑶在砖坯侧面打码，并抛平砖坯表层；⑷砖坯输送至底釉房喷上底釉；⑸识别砖坯侧面码数，并打印对应表面数码装饰图案；⑹图案装饰砖坯输送至面釉房喷上面釉；⑺砖坯进窑炉烧成，烧结温度为1150～1250℃。

Description

具有多色透光立体效果陶瓷岩板及其制造方法
技术领域
本发明属于陶瓷岩板技术领域，特别涉及一种具有多色透光立体效果陶瓷岩板及其制造方法。
背景技术
随着人们生活水平的不断提高，家居装修的消费者对陶瓷岩板产品要求越来越高，当前千篇一律单纯依靠对版面设计呈现给消费者的产品已不足以吸引消费者目光，需通过开发具有个性化的产品才能满足消费者日益增长的审美需求。
从陶瓷岩板市场可发现，现在许多陶瓷生产厂家都已不仅仅专注于表面的装饰，表面之下的砖体装饰也越来越受到关注，目前出现各种类型的产品主要有以下几种：
第一种是普通的通体陶瓷岩板产品，主要特征是砖体有图案效果，而且颜色与表面装饰图案比较接近，其表面和砖体纹理比较丰富，主要不足是砖体图案跟表面的装饰图案没有很好的对应关系，与石材相比不能做到真正通体，且砖体不具有透光性，从陶瓷岩板表面看不到砖体图案，只能通过切割倒边有所体现；
第二种是具有对位效果的通体陶瓷岩板产品，其主要特征是在上面所说产品上升级，砖体不但有纹理图案，而且纹理图案能与表面装饰图案一一对应，可以很好的模仿石材的通体纹理效果，但就是砖体不具有透光性，纹理的呈现也只能通过倒边切割才能体现；
第三种是具有透光效果的陶瓷岩板产品，这类型产品主要特征是砖坯采用具有透光性能的粉料制备而成，灯光从下往上照射，产品表面可以看到底下光线，表面装饰图案则会呈现出琥珀态纹理效果，但目前市场上透光产品还都只有纯白色产品，砖体的实现只使用一个白色粉料通体压制而成，没有图案效果，产品缺乏纹理层次感。
发明内容
针对上述几种产品类型所出现的问题，本发明的目的在于提供一种能够将砖坯中的图案色彩层次、与表面装饰一一对应纹理效果、透光性能充分体现出来的一种具有多色透光立体效果陶瓷岩板及其制造方法。
本发明的技术解决方案是所述具有多色透光立体效果陶瓷岩板，其特殊之处在于，由从下到上依次叠设的坯体层、底釉层、表面图案层、面釉层构成的复合层结构组成；其中底釉釉料按重量百分比由以下组份组成：霞石25～35％、原矿球土8～10％、煅烧高岭土10～13％、锂铝硅废玻璃粉15～25％、锂瓷石9～15％、硅灰石8～12％、氢氧化铝7～10％、硅酸锆0～10％、325目超细石英3～5％；底釉釉浆细度控制为过325目筛余0.5～0.7％；所述多色透光立体效果陶瓷岩板砖坯输送至底釉房后，采用高压喷釉柜喷上底釉，喷釉工艺参数为：釉工作比重为1.23～1.30，釉量为300～500g/m2；高压喷釉柜安装3～5支喷枪，喷枪的喷嘴大小为0.31～0.42mm，喷枪喷釉的工作压力为10～15bar；其中面釉釉料按重量百分比由以下组份组成：钠长石粉25～32％、球土8～10％、煅烧高岭土10～12％、锂铝硅废玻璃粉25～30％、锂瓷石8～10％、硅灰石8～12％、氧化锌5～8％、氢氧化铝7～10％；面釉釉浆细度控制为过325目筛余0.3～0.5％；图案装饰砖坯输送至面釉房喷上面釉后，采用高压喷釉柜喷上面釉，喷面釉工艺参数为：釉工作比重为1.23～1.40，根据透光陶瓷岩板产品釉面效果，喷釉的釉量为200～400g/m2；其中高压喷釉柜安装3～5支喷枪，喷枪的喷嘴大小为0.31～0.42mm，喷枪喷釉的工作压力为10～15bar。
本发明的另一技术解决方案是所述具有多色透光立体效果陶瓷岩板的制造方法，其特殊之处在于，包括以下步骤：
⑴多种彩色透光配方制备；
⑵坯体根据设置图案布料，并压制成型；
⑶在砖坯侧面打码，并抛平砖坯表层；
⑷砖坯输送至底釉房喷上底釉；
⑸识别砖坯侧面码数，并打印对应表面数码装饰图案；
⑹图案装饰后砖坯输送至面釉房喷上面釉；
⑺砖坯进窑炉烧成，烧结温度1150～1250℃,高火保温时间13～17分钟，烧成时间115～135分钟。
作为优选：步骤⑸所述表面数码装饰图案采用8～12通道喷墨设备进行透光岩板产品图案、颜色效果的装饰，其墨水颜色有蓝、深棕、红棕、金黄、钒锆黄、黑、绿、大红、白，其图案形成包括如下步骤：
(5.1)根据上述扫描文件处理得到喷墨设备可识别的PSB喷墨文件；
(5.2)识别砖坯的数字编码；
(5.3)喷墨设备根据识别数据确定需打印文件；
(5.4)砖坯居中调整位置；
(5.5)打印相对应PSB喷墨文件。
本发明的再一技术解决方案是所述具有多色透光立体效果陶瓷岩板的制造方法，其特殊之处在于，坯体层布料，包括以下步骤：
⑴高清扫描样板表面图案，并形成扫描文件；
⑵扫描文件经处理后转换成可输入坯体数码布料设备的RGB格式文件；
⑶在RGB文件的纹理图案中提取一种或者多种单色元素；
⑷按照单色元素的颜色，制备出对应彩色透光粉料，并储存陈腐；
⑸一种或者多种彩色透光粉料输送至坯体布料设备的储备料罐待用；
⑹坯体布料装置根据RGB文件的图案纹理完成坯体层布料。
作为优选：步骤⑴进一步包括以下步骤：
(1.1)打码设备在砖坯侧面固定位置喷上数字编码；
(1.2)砖坯打码一侧安装感应探头和高清拍照设备，当砖坯经过探头，则拍照设备启动，拍下数字编码高清照片；
(1.3)电脑识别高清照片，把对应的数字信号输送至喷墨设备。
作为优选：步骤⑷所述彩色透光粉料由透光坯体的基础粉料与着色剂按97～100wt％︰0～5wt％比例进行干混或球磨组浆、喷粉造粒而成。
作为优选：所述的彩色透光粉料颗粒级配控制：30目筛上0.5wt％，30目～40目筛上20wt％～35wt％，40～60目筛上45wt％～60wt％，60～80目筛上5wt％～10wt％，80～100目筛上2wt％～5wt％，100目筛下0～1wt％；粉体的休止角要小于30°，粉体水份控制为4.5～5.0wt％，霍尔流速计检测流动性为60～80s，为能满足粉体流动性能要求，需在粉体中加入粉体润滑剂，所述的粉体润滑剂为脱脂磷酸钙，加入配比1～3wt％。
作为优选：所述基础粉料，按重量百分比由以下组份组成：锂铝硅废玻璃粉45～50％、高塑性泥料20～25％、钾钠石粉0～3％、透锂长石7～12％、锂霞石粉0～7％、钡长石3～8％、硼砂0.5～3％。
作为优选：所述的着色剂由红色、蓝色、棕色、黄色、黑色、绿色中的一种或者多种物料组合而成；
其中所述的红色着色剂为锆铁红，其按照配方重量百分比组成如下:二氧化锆45～55wt％、硅石30～35wt％、硫酸亚铁10～20wt％、氟化钠3～6wt％、氯化钠0～3wt％；
其中所述的蓝色着色剂为钴蓝，其按照配方重量百分比组成如下:氧化钴10～30wt％、氧化铝20～35wt％、石英25～40wt％、氧化锌0～10wt％、长石7～10wt％、硼砂4～12wt％；
其中所述的棕色着色剂为铬钛棕，其按照配方重量百分比组成如下:二氧化钛10～30％、碳酸钙25～35wt％、石英30～45wt％、重铬酸钾5～10wt％、氯化钠10～30wt％；
所述的黄色着色剂为钒锆黄，其按照配方重量百分比组成如下:二氧化锆10～30wt％、偏钒酸铵15～35wt％、五氧化二钒50～70wt％；
其中所述的黑色着色剂按照配方重量百分比组成如下:三氧化二铁10～30wt％、三氧化二铬15～35wt％、二氧化锰20～40wt％、氧化钴50～10wt％、氧化镍50～10wt％、氧化铜15～20wt％；
其中所述的绿色着色剂为铬绿，其按照配方重量百分比组成如下:萤石10～30wt％、碳酸钙15～35wt％、石英20～40wt％、重铬酸钾5～10wt％、硅石0～5wt％、石灰石0～10wt％、氯化钙5～15wt％、三氧化二铬20～30wt％、氟化锂0～10wt％。
与现有技术相比，本发明的有益效果:
⑴本发明所述的坯体布料设备采用机械手布料设备、多通道线条通体布料设备或多通道细纹通体陶瓷的微孔数码布料设备，实现多色透光坯由面至底的立体通体纹理效果。
⑵本发明所述多色透光立体效果陶瓷岩板产品可根据文件设置透出对应彩光；
⑶本发明砖体中的图案色彩层次、与表面装饰一一对应纹理效果、透光性能充分体现出来。
附图说明
图1是本发明陶瓷岩板制造方法的工艺流程图；
图2是本发明干混单色色料坯体透光色调图。
具体实施方式
本发明下面将结合实施例作进一步详述：
实施例1
具有多色透光立体效果陶瓷岩板，由从下到上依次叠设的坯体层、底釉层、表面图案层、面釉层构成的复合层结构组成；底釉釉料按重量百分比由以下组份组成：霞石30％、原矿球土8％、煅烧高岭土12％、锂铝硅废玻璃粉16％、锂瓷石9％、硅灰石10％、氢氧化铝10％、硅酸锆2％、325目超细石英3％；底釉釉浆细度控制为过325目筛余0.5～0.7％；所述多彩纹理透光砖体输送至底釉房后，采用高压喷釉柜喷上底釉，喷釉工艺参数为：釉工作比重为1.25±0.02，釉量为450±5g/m2；其中高压喷釉柜中安装4支喷枪，喷枪的喷嘴大小为0.35mm，喷枪喷釉的工作压力为12bar；所述面釉釉料，按重量百分比由以下组份组成：钠长石粉25～32％、球土8～10％、煅烧高岭土10～12％、锂铝硅废玻璃粉25～30％、锂瓷石8～10％、硅灰石8～12％、氧化锌5～8％、氢氧化铝7～10％；面釉釉浆细度控制为过325目筛余0.3～0.5％；图案装饰砖坯输送至面釉房喷上面釉后，采用高压喷釉柜喷上面釉，喷面釉工艺参数为：釉工作比重为1.30±0.02，透光陶瓷岩板产品釉面效果为亚光自然面，喷釉的釉量为230±3g/m2；其中高压喷釉柜中安装3支喷枪，喷枪的喷嘴大小为0.31mm，喷枪喷釉的工作压力为10bar。
参照图1所示，所述具有多色透光立体效果陶瓷岩板的制造方法，包括以下步骤：
⑴多种彩色透光配方制备；
⑵坯体根据设置图案布料，并压制成型；
⑶在砖坯侧面打码，并抛平砖体表层；
⑷砖体输送至底釉房喷上底釉；
⑸识别砖体侧面码数，并打印对应表面数码装饰图案；
步骤⑸所述表面数码装饰图案采用12通道喷墨设备进行透光岩板产品图案、颜色效果的装饰，其墨水颜色有蓝、深棕、红棕、金黄、钒锆黄、黑、绿、大红、白，其图案形成包括如下步骤：
(5.1)根据上述扫描文件处理得到喷墨设备可识别的PSB喷墨文件；
(5.2)识别砖坯的数字编码；
(5.3)喷墨设备根据识别数据确定需打印文件；
(5.4)砖坯居中调整位置；
(5.5)打印相对应PSB喷墨文件；
⑹图案装饰后砖坯输送至面釉房喷上面釉；
⑺砖体进窑炉烧成，烧结温度为1150～1250℃；
步骤⑺所述烧成采用的窑炉长度为450m、宽度为2.2m、烧成温度1170～1215℃，高火保温时间13分钟，烧成时间115分钟。
所述具有多色透光立体效果陶瓷岩板坯体层的制造方法，包括以下步骤：
⑴高清扫描样板表面图案，并形成扫描文件；如果是拍照图像，识别采用拍照图像识别方法：第一、打码设备在砖坯侧面固定位置喷上数字编码；第二、砖坯打码一侧安装感应探头和高清拍照设备，当砖坯经过探头，则拍照设备启动，拍下数字编码高清照片，第三，电脑识别高清照片，对应的数字信号输送至喷墨设备；
⑵扫描文件经处理后转换成可输入坯体数码布料设备的RGB格式文件；
⑶在RGB文件的纹理图案中提取一种或者多种单色元素；
⑷按照单色元素的颜色，制备出彩色透光粉料，并储存陈腐；
所述彩色透光粉料由透光坯体的基础粉料与着色剂按99.9wt％：0.1wt％比例进行干混而成，彩色透光粉料压制烧成后透光色调效果如图2所示，可见不同彩色透光粉料透光发色情况不同，可根据产品需要效果进行调整基础坯体粉料中着色剂比例，得到理想的不同色调透光陶瓷岩板产品；
所述的彩色透光粉料颗粒级配控制：30目筛上0.5wt％，30目～40目筛上20wt％，40～60目筛上55wt％，60～80目筛上5wt％～10wt％，80～100目筛上2wt％，100筛下1wt％；粉体的休止角25°，粉体水份控制为4.5～5.0wt％，霍尔流速计检测流动性为65s，为能满足粉体流动性能要求，需在粉体中加入粉体润滑剂，所述的粉体润滑剂脱脂磷酸钙，加入配比1.5wt％；所述基础粉料，按重量百分比由以下组份组成：锂铝硅废玻璃粉50％、高塑性泥料25％、钾钠石粉1％、透锂长石10％、锂霞石粉5％、钡长石8％、硼砂1％。
所述的着色剂由红色、蓝色、棕色、黄色、黑色、绿色中的一种或者多种物料组合而成；
其中所述的红色着色剂为锆铁红，其按照配方重量百分比组成如下:二氧化锆55wt％、硅石30wt％、硫酸亚铁10wt％、氟化钠4wt％、氯化钠1wt％；
其中所述的蓝色着色剂为钴蓝，其按照配方重量百分比组成如下:氧化钴30wt％、氧化铝25wt％、石英25wt％、氧化锌7wt％、长石8wt％、硼砂5wt％；
其中所述的棕色着色剂为铬钛棕，其按照配方重量百分比组成如下:
二氧化钛15wt％、碳酸钙30wt％、石英35wt％、重铬酸钾7wt％、氯化钠13wt％；
所述的黄色着色剂为钒锆黄，其按照配方重量百分比组成如下:二氧化锆25％、偏钒酸铵20wt％、五氧化二钒55wt％；
其中所述的黑色按照配方重量百分比组成如下:三氧化二铁10wt％、三氧化二铬25wt％、二氧化锰35wt％、氧化钴6wt％、氧化镍8wt％、氧化铜16wt％；
其中所述的绿色着色剂为铬绿，其按照配方重量百分比组成如下:萤石10wt％、碳酸钙20wt％、石英25wt％、重铬酸钾5wt％、硅石2wt％、石灰石5wt％、氯化钙10wt％、三氧化二铬22wt％、氟化锂1wt％；
⑸一种或者多种彩色透光粉料输送至坯体布料设备的储备料罐待用；
⑹坯体布料装置根据RGB文件的图案纹理完成砖坯层制作。
以上所述仅为本发明的较佳实施例，凡依本发明权利要求范围所做的均等变化与修饰，皆应属本发明权利要求的涵盖范围。

Claims (9)

1.一种具有多色透光立体效果陶瓷岩板，其特征在于，由从下到上依次叠设的坯体层、底釉层、表面图案层、面釉层构成的复合层结构组成；
其中底釉釉料按重量百分比由以下组份组成：霞石25～35％、原矿球土8～10％、煅烧高岭土10～13％、锂铝硅废玻璃粉15～25％、锂瓷石9～15％、硅灰石8～12％、氢氧化铝7～10％、硅酸锆0～10％、325目超细石英3～5％；底釉釉浆细度控制为过325目筛余0.5～0.7％；所述多色透光立体效果陶瓷岩板砖坯输送至底釉房后，采用高压喷釉柜喷上底釉，喷釉工艺参数为：釉工作比重为1.23～1.30，釉量为300～500g/m2；高压喷釉柜安装3～5支喷枪，喷枪的喷嘴大小为0.31～0.42mm，喷枪喷釉的工作压力为10～15bar；
其中面釉釉料按重量百分比由以下组份组成：钠长石粉25～32％、球土8～10％、煅烧高岭土10～12％、锂铝硅废玻璃粉25～30％、锂瓷石8～10％、硅灰石8～12％、氧化锌5～8％、氢氧化铝7～10％；面釉釉浆细度控制为过325目筛余0.3～0.5％；经图案装饰后的多色透光立体效果陶瓷岩板砖坯输送至面釉房喷上面釉后，采用高压喷釉柜喷上面釉，喷面釉工艺参数为：釉工作比重为1.23～1.40，根据透光陶瓷岩板产品釉面效果，喷釉的釉量为200～400g/m2；其中高压喷釉柜安装3～5支喷枪，喷枪的喷嘴大小为0.31～0.42mm，喷枪喷釉的工作压力为10～15bar。
2.一种具有多色透光立体效果陶瓷岩板的制造方法，其特征在于，包括以下步骤：
⑴多种彩色透光配方制备；
⑵坯体根据设置图案布料，并压制成型；
⑶在砖坯侧面打码，并抛平砖坯表层；
⑷砖坯输送至底釉房喷上底釉；
⑸识别砖坯侧面码数，并打印对应表面数码装饰图案；
⑹图案装饰后砖坯输送至面釉房喷上面釉；
⑺砖坯进窑炉烧成，烧结温度1150～1250℃,高火保温时间13～17分钟，烧成时间115～135分钟。
3.根据权利要求1所述具有多色透光立体效果陶瓷岩板的制造方法，其特征在于，步骤⑸所述表面数码装饰图案采用8～12通道喷墨设备进行透光岩板产品图案、颜色效果的装饰，其墨水颜色有蓝、深棕、红棕、金黄、钒锆黄、黑、绿、大红、白，其图案形成包括如下步骤：
(5.1)根据上述扫描文件处理得到喷墨设备可识别的PSB喷墨文件；
(5.2)识别砖坯的数字编码；
(5.3)喷墨设备根据识别数据确定需打印文件；
(5.4)砖坯居中调整位置；
(5.5)打印相对应PSB喷墨文件。
4.一种具有多色透光立体效果陶瓷岩板的制造方法，其特征在于，坯体层布料，包括以下步骤：
⑴高清扫描样板表面图案，并形成扫描文件；
⑵扫描文件经处理后转换成可输入坯体数码布料设备的RGB格式文件；
⑶在RGB文件的纹理图案中提取一种或者多种单色元素；
⑷按照单色元素的颜色，制备出对应彩色透光粉料，并储存陈腐；
⑸一种或者多种彩色透光粉料输送至坯体布料设备的储备料罐待用；
⑹坯体布料装置根据RGB文件的图案纹理完成坯体层布料。
5.根据权利要求4所述具有多色透光立体效果陶瓷岩板的制造方法，其特征在于，步骤⑴进一步包括以下步骤：
(1.1)打码设备在砖坯侧面固定位置喷上数字编码；
(1.2)砖坯打码一侧安装感应探头和高清拍照设备，当砖坯经过探头，则拍照设备启动，拍下数字编码高清照片；
(1.3)电脑识别高清照片，把对应的数字信号输送至喷墨设备。
6.根据权利要求4所述具有多色透光立体效果陶瓷岩的制造方法，其特征在于，步骤⑷所述彩色透光粉料由透光坯体的基础粉料与着色剂按97～100wt％︰0～5wt％比例进行干混或球磨组浆、喷粉造粒而成。
7.根据权利要求6所述具有多色透光立体效果陶瓷岩板的制造方法，其特征在于，所述的彩色透光粉料颗粒级配控制：30目筛上0～0.5wt％，30目～40目筛上20wt％～35wt％，40～60目筛上45wt％～60wt％，60～80目筛上5wt％～10wt％，80～100目筛上2wt％～5wt％，100目筛下0～1wt％；粉体的休止角要小于30°，粉体水份控制为4.5～5.0wt％，霍尔流速计检测流动性为60～80s，为能满足粉体流动性能要求，需在粉体中外加入粉体润滑剂，所述的粉体润滑剂为脱脂磷酸钙，加入配比1～3wt％。
8.根据权利要求6所述具有多色透光立体效果陶瓷岩板的制造方法，其特征在于，所述基础粉料，按重量百分比由以下组份组成：锂铝硅废玻璃粉45～50％、高塑性泥料20～25％、钾钠石粉0～3％、透锂长石7～12％、锂霞石粉0～7％、钡长石3～8％、硼砂0.5～3％。
9.根据权利要求6所述具有多色透光立体效果陶瓷岩板的制造方法，其特征在于，所述的着色剂由红色、蓝色、棕色、黄色、黑色、绿色中的一种或者多种物料组合而成；
其中所述的红色着色剂为锆铁红，其按照配方重量百分比组成如下:二氧化锆45～55wt％、硅石30～35wt％、硫酸亚铁10～20wt％、氟化钠3～6wt％、氯化钠0～3wt％；
其中所述的蓝色着色剂为钴蓝，其按照配方重量百分比组成如下:氧化钴10～30wt％、氧化铝20～35wt％、石英25～40wt％、氧化锌0～10wt％、长石7～10wt％、硼砂4～12wt％；
其中所述的棕色着色剂为铬钛棕，其按照配方重量百分比组成如下:二氧化钛10～20wt％、碳酸钙25～35wt％、石英30～45wt％、重铬酸钾5～10wt％、氯化钠10～15wt％；
所述的黄色着色剂为钒锆黄，其按照配方重量百分比组成如下:二氧化锆10～30％、偏钒酸铵15～35wt％、五氧化二钒50～70wt％；
其中所述的黑色着色剂按照配方重量百分比组成如下:三氧化二铁10～15wt％、三氧化二铬20～30wt％、二氧化锰30～40wt％、氧化钴5～10wt％、氧化镍5～10wt％、氧化铜15～20wt％；
其中所述的绿色着色剂为铬绿，其按照配方重量百分比组成如下:萤石10～30wt％、碳酸钙15～35wt％、石英20～40wt％、重铬酸钾5～10wt％、硅石0～5wt％、石灰石0～10wt％、氯化钙5～15wt％、三氧化二铬20～30wt％、氟化锂0～10wt％。
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