CN114276127B - Porcelain tile with weathered stone texture and production method thereof - Google Patents

Porcelain tile with weathered stone texture and production method thereof Download PDF

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Publication number
CN114276127B
CN114276127B CN202111602105.0A CN202111602105A CN114276127B CN 114276127 B CN114276127 B CN 114276127B CN 202111602105 A CN202111602105 A CN 202111602105A CN 114276127 B CN114276127 B CN 114276127B
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powder
conveying belt
ink
belt
penetrating ink
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CN114276127A (en
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夏昌奎
王美霞
余剑峰
甄燕萍
蒋孝云
曹承鑫
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Deqing Nabel Ceramic Co ltd
Jiujiang Nabel Ceramic Co ltd
Hangzhou Nabel Ceramic Co ltd
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Deqing Nabel Ceramic Co ltd
Jiujiang Nabel Ceramic Co ltd
Hangzhou Nabel Ceramic Co ltd
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes

Abstract

The invention discloses a production method of porcelain tiles with weathered stone textures, which comprises the following steps: A. preparing a green body powder group for the porcelain tile with the weathered stone texture according to a conventional method; B. adopting a digital whole-body material distribution system to distribute materials; C. press forming, D, drying the blank; E. identifying textures; F. inkjet decoration; G. firing; H. edging and polishing; I. and (5) treating the simulated weathering effect to obtain the porcelain tile with the weathered stone texture. The invention forms stone textures with rich and flexible colors on the surface of the green body, and solves the problems that the exposed texture, color and surface contrast are large, the decoration effect is not coordinated and the exposed bottom is not beautiful in the later deep processing of ceramic bricks such as edging, slotting, chamfering and the like. Meanwhile, the special textures formed by long-term natural environment weathering of natural stone can be presented by spraying the weathering-imitating functional reagent on the surface of the porcelain tile with the weathering stone textures after edging and polishing.

Description

Porcelain tile with weathered stone texture and production method thereof
Technical Field
The invention relates to a porcelain tile and a production method thereof, in particular to a porcelain tile with weathered stone textures and a production method thereof.
Background
The building ceramic industry in China has been developed for decades, the production and manufacturing level is greatly improved, and the product quality and the decoration level can be compared with those of the foreign advanced countries. In the aspect of ceramic tile decoration technology, the development process mainly goes through three stages: namely screen lithographic decoration, glue roll printing decoration and digital inkjet printing decoration. The digital ink-jet printing decoration is a non-contact digital printing technology, can print irregular surfaces, does not need real-object plate making, is simple in plate conversion and good in production repeatability, improves printing accuracy by directly spraying printing on a blank, increases the 60-100DPI resolution of the traditional silk screen and rubber roller printing to 360DPI or higher at one time, and simultaneously realizes feasibility of multi-variable pattern modeling application, and ink-jet can be performed on 3D three-dimensional concave-convex brick surfaces, so that the produced ceramic tile is more vivid in image and is closer to nature.
Although the digital ink-jet printing decoration solves the problem that the color of the surface of the ceramic tile is not lifelike, the later deep processing of the ceramic tile such as edging, slotting, chamfering and the like has the problems that the exposed texture, color and luster of the base blank are large in contrast with the surface, the decoration effect is not coordinated, and the exposed base is not attractive. In the aspect of realizing the full-body stone texture, chinese patent CN201910066018.4 discloses a full-body unglazed marble ceramic tile and a manufacturing method thereof, the full-body texture of the ceramic tile is endowed by combining multi-pipe free cloth with dry polishing, but in order to protect the surface texture, a transparent wear-resistant protection material is added to serve as a protection layer after inkjet decoration, the multi-pipe free cloth easily causes overlarge texture randomness, so that the blank texture is difficult to be completely matched with the inkjet texture, and after the dry polishing process is used, the presented textures are different due to different polishing depths, so that the increase of the dry polishing process brings great difficulty to texture control.
Disclosure of Invention
The invention provides a production method of a porcelain tile with weathered stone texture, which aims to solve the problems that the exposed texture, color and surface contrast are large, the decoration effect is not coordinated and the exposed bottom is not attractive in the later deep processing of ceramic tiles such as edging, slotting and chamfering, and the like, and to realistically reproduce the special texture formed by the long-term natural environment weathering effect of natural stone.
It is another object of the present invention to provide a porcelain tile with weathered stone texture produced by the production method.
In order to achieve the first object, the present invention adopts the following technical scheme: the production method of the porcelain tile with the weathered stone texture comprises the following steps:
A. preparing a green body powder group for the porcelain tile with the weathered stone texture according to a conventional method, wherein the green body powder group consists of four green body powder with different chemical compositions: a first material powder, a second material powder, a third material powder and a fourth material powder; wherein the chemical composition of the first material powder is as follows by weight percent: siO (SiO) 2 65%~68%，Al 2 O 3 18~22%，CaO 2.5~3.5%，MgO 0.1~1%，K 2 O 2~3%，Na 2 O 1.5~2.5%，ZnO0.1%~1%，Fe 2 O 3 ≤1%，TiO 2 Less than or equal to 0.3 percent and IL less than or equal to 5 percent, wherein the chemical composition of the second material powder is as follows by weight percent: siO (SiO) 2 67%~70%，Al 2 O 3 17~20%，CaO 0~1%，MgO 9~13%，K 2 O 1~2%，Na 2 O 0.5~1.5%，ZnO0.1%~1%，Fe 2 O 3 ≤0.7%，TiO 2 Less than or equal to 0.2 percent and less than or equal to 5 percent of IL, wherein the chemical composition of the third material powder is as follows by weight percent: siO (SiO) 2 68%~73%，Al 2 O 3 3~7%，CaO 18~23%，MgO 0.1~1%，K 2 O 0~0.3%，Na 2 O 0~0.3%，Fe 2 O 3 ≤1%，TiO 2 Less than or equal to 0.5 percent and IL less than or equal to 3 percent, and the chemical composition of the fourth material powder is as follows by weight percent: siO (SiO) 2 68%~71%，Al 2 O 3 13~17%，CaO 0.5~2%，MgO 0.1~1%，K 2 O 3~5%，Na 2 O 4~6%，ZnO0.1%~1%，Fe 2 O 3 ≤1%，TiO 2 Less than or equal to 0.5 percent and IL less than or equal to 5 percent for standby;
B. cloth: d, adopting a digital whole body distribution system to distribute the green body powder group for the porcelain tile with the weathered stone texture, so as to form a whole body green body powder layer;
C. and (3) forming: pushing the powder layer of the whole body blank body formed by the cloth in the step B into a die cavity, and pressing and forming to form a porcelain tile blank body with weathered stone textures;
D. drying the green body: c, drying the ceramic tile blank body with the weathered stone texture formed in the step C according to a conventional method;
E. texture recognition: d, identifying the texture of the dried green body in the step D by adopting a texture collector, and sending a network signal to a digital ink-jet printer;
F. inkjet decoration: preparing a penetrating inkjet ink set, including penetrating ink 1, penetrating ink 2, penetrating ink 3, penetrating ink 4, penetrating ink 5, penetrating ink 6 and penetrating ink 7; the penetrating ink 1 is a composition for coloring by iron ions, the penetrating ink 2 is a composition for coloring by chromium ions and titanium ions, the penetrating ink 3 is a composition for coloring by cobalt ions, the penetrating ink 4 is a composition for coloring by iron ions and cobalt ions, the penetrating ink 5 is a composition for coloring by chromium ions and tin ions, the penetrating ink 6 is a composition for coloring by chromium ions, and the penetrating ink 7 is a composition for coloring by gold ions; the digital ink-jet printer receives the network signal sent by the texture collector in the step E, and then calls out an ink-jet pattern of the corresponding stone texture, and then the penetrating ink-jet ink group is aligned and jet-printed on the surface of the porcelain tile blank body with the weathered stone texture after the texture identification in the step E according to the ink-jet pattern of the corresponding stone texture;
G. Firing: placing the ceramic tile blank with the weathered stone texture after the ink-jet decoration in the step F into a roller kiln for firing, wherein the firing temperature is 1150-1250 ℃, and the firing period is 60-150 min, so as to obtain a ceramic tile sintered body with the weathered stone texture;
H. edging and polishing: performing edging and polishing treatment on the ceramic tile sintered body with the weathered stone texture obtained by sintering in the step G by using conventional edging and polishing processing equipment to obtain a semi-finished product of the ceramic tile with the weathered stone texture;
I. and (3) treating the simulated weathering effect: preparing a weathering functional reagent, and spraying the weathering functional reagent on the surface of the porcelain tile semi-finished product with the weathering stone texture after edging and polishing in the step H to obtain a porcelain tile finished product with the weathering stone texture; the weathering simulating functional agent comprises hydrofluoric acid, benzoic acid and hydrochloric acid.
Further, in the step A, the first material powder, the second material powder and the fourth material powder all contain 1% -8% of amorphous silica.
Further, in the step A, the third material powder contains 0.5% -2% of tin dioxide.
Further, the digital whole body distribution system in the step B comprises an intelligent software control system and a whole body distribution device; the whole-body distributing device comprises a frame, a first transmission belt, a line forming system, a powder supplementing system and a particle forming system; the line forming system comprises a thick line forming system, a medium line forming system and a thin line forming system; the thick line forming system comprises a thick line distributing hopper positioned at the starting end of the advancing direction of the first conveying belt, a first sub-conveying belt positioned below the thick line distributing hopper, and a second sub-conveying belt positioned below the first sub-conveying belt; the medium line forming system comprises an engraving belt at the front end of the second sub-transmission belt along the advancing direction of the first transmission belt, a powder scraping hopper clung to the surface of the engraving belt, a third sub-transmission belt positioned above the powder scraping hopper and a medium line distributing hopper positioned above the third sub-transmission belt; the fine wire forming system comprises an inclined baffle plate at the front end of the third sub-conveying belt along the advancing direction of the first conveying belt and a fine wire distributing hopper above the inclined baffle plate; the powder supplementing system comprises a scraping hopper, a fourth conveying belt and a powder supplementing hopper, wherein the scraping hopper is used for inclining the front end of the baffle plate along the advancing direction of the first conveying belt, the fourth conveying belt is arranged above the scraping hopper, and the powder supplementing hopper is arranged above the fourth conveying belt; the particle forming system comprises a screen mesh at the front end of a fourth-minute transmission belt along the advancing direction of the first transmission belt, a scraping belt closely attached to the screen mesh, and a fifth-minute transmission belt above the scraping belt along the advancing direction of the first transmission belt, wherein a jacking device and a particle powder material distributing hopper are sequentially distributed on the fifth-minute transmission belt; the width of the thick line forming system and the medium line forming system in the direction perpendicular to the first conveying belt is smaller than that of the first conveying belt.
The working process of the digital whole body distribution system in the step B is as follows: firstly, inputting a digital fossil texture pattern through an intelligent software control system, driving a whole body distributing device to distribute according to the digital fossil texture pattern, then sequentially blanking a coarse line distributing hopper in the whole body distributing device, forming a powder layer on a first sub-conveying belt, dropping the powder layer onto a second sub-conveying belt along with the transmission of the first sub-conveying belt, then swinging the second sub-conveying belt along a direction perpendicular to the advancing direction of the first conveying belt to discharge powder onto the first conveying belt, forming arc-shaped coarse lines on the first conveying belt due to the fact that the first conveying belt always moves along the advancing direction, and when the first conveying belt carrying the coarse line powder moves to the lower part of a medium line forming system, the middle line material distribution hopper starts to discharge, a powder material layer is formed on a third sub-conveying belt in a lamination discharging mode, the powder material layer falls into a powder scraping hopper along with the movement of the third sub-conveying belt, powder material at the concave position of the carving belt is conveyed to a gap position of thick line powder material on a first conveying belt by the carving belt through the interaction of the powder scraping hopper and the carving belt, the powder scraping hopper and the carving belt do swinging movement along the direction perpendicular to the advancing direction of the first conveying belt in the discharging process, irregular arc-shaped distribution is formed on the first conveying belt, the carving belt is designed into concave stripes with a certain width, so that the width of arc-shaped powder material formed by the powder material at the concave position on the first conveying belt is smaller than that of arc-shaped powder material formed by a thick line material distribution system, when the first conveying belt carrying the coarse line powder layer and the medium line powder layer moves to the lower part of the fine line forming system, the fine line material distributing hopper starts to intermittently feed, powder falls onto the inclined baffle plate and then slides to the gap between the coarse line powder layer and the medium line powder layer on the first conveying belt, after that, when the first conveying belt carrying the coarse line powder layer, the medium line powder layer and the fine line powder layer moves to the lower part of the powder supplementing system, the powder supplementing hopper starts to feed, sequentially falls onto the fourth conveying belt to form laminated powder layers, then falls onto the scraping hopper, the powder supplementing powder is applied to the gaps among the coarse line powder layer, the medium line powder layer and the fine line powder layer on the first conveying belt through the scraping hopper, the powder layers after the powder supplementing operation are conveyed to the lower part of the particle forming system by the first conveying belt, the particle powder distributing hopper starts to discharge and fall onto a fifth conveying belt, then the fifth conveying belt conveys powder to a jacking device, the jacking device starts to work and pre-presses the powder to form powder blocks with a certain degree of compactness, the powder blocks move along with the fifth conveying belt and fall onto a screen with a scraping sheet, then the scraping sheet moves back and forth along the direction perpendicular to the moving direction of the first conveying belt, the powder blocks are extruded through the screen, particles with the same size as the aperture of the screen are extruded through the screen, the particles fall onto a powder layer on the first conveying belt, the powder layer is completed by powder supplement, the screen and the first conveying belt have a certain height difference due to the certain weight of the particles, the powder layer with the powder supplement is embedded under the action of gravity to form a final blank powder layer with a certain texture, and then, feeding the blank powder material layer with certain texture into a die cavity of a press through a first conveying belt for back pressure molding.
Further, the second sub-conveying belt, the powder scraping hopper and the carving belt in the whole-body material distributing device do swinging motion along the advancing direction perpendicular to the first conveying belt, the swinging frequency of the second sub-conveying belt is lower than that of the powder scraping hopper and the carving belt, and the swinging pace of the second sub-conveying belt is inconsistent with that of the powder scraping hopper and the carving belt.
Further, the particle forming system in the whole body distributing device is in intermittent motion.
Further, the viscosity of the penetrating ink-jet ink set in the step F is 25-35 mPa.s, the test flow rate of the 50mL flow rate cup is 11-15 s, and the specific gravity is 0.88-0.92 g/cm 3 The surface tension is 23-29 mN/m.
Further, the color of the penetrating inkjet ink set in the step F is not fixed, and may show different colors in green body powder materials of different systems; for the first, second and fourth material powders, the penetrating ink 1 appears iron red, the penetrating ink 2 appears yellow, the penetrating ink 3 appears sea bluish, the penetrating ink 4 appears black, the penetrating ink 5 appears light yellow, the penetrating ink 6 appears yellow-green, and the penetrating ink 7 appears pink; for the third material powder, the penetrating ink 1 is yellow, the penetrating ink 2 is yellow gray, the penetrating ink 3 is marine blue, the penetrating ink 4 is blue, the penetrating ink 5 is rose red, the penetrating ink 6 is green, and the penetrating ink 7 is pink; for the first material powder, the second material powder and the fourth material powder, although the color development hues of 7 kinds of penetrating inks in the 3 material powders are consistent, the saturation of the color development is different, and for penetrating ink 1, penetrating ink 2, penetrating ink 3, penetrating ink 4, penetrating ink 5 and penetrating ink 6, the order of the color development saturation from high to low is: the fourth material powder is larger than the first material powder and larger than the second material powder; for the penetrating ink 7, the color saturation is ordered from high to low: the second material powder is larger than the fourth material powder and larger than the first material powder.
The same penetrating ink can present different colors in green body powder materials of different systems, and mainly refers to different hues, which can also be called different hues, wherein the hues refer to the looks of the colors, are the most main basic characteristics for distinguishing the colors, and represent the difference of color quality. The penetrating ink is colored in the green body powder, and in-situ reaction is carried out to form a coloring compound which can selectively absorb light, so that the reflecting radiation effect on light with different wavelengths is formed, and different colors are formed. For example, the penetrating ink 5 is a composition of chromium ion and tin ion, which is a composite coloring material of a first material powder, a second material powder and a fourth material powderLight yellow color is exhibited due to the in situ reaction of chromium ions with titanium oxide in a potassium sodium system to form a chromium-titanium yellow solid solution; the penetrating ink 5 shows rose red in the third material powder, because the calcium oxide and the silicon oxide in the third material powder react with the tin ions in the penetrating ink 5 in situ to form tin sphene (CaSnSiO 5 ) The chromium ions in the penetrating ink 5 form Cr in an oxidizing atmosphere 2 O 3 And is dissolved in the sphene lattice so that the in-situ reaction of the third material powder and the penetrating ink 5 presents rose red, and the saturation of the rose red is enhanced as the content of the sphene increases.
The powder of the blank body of the same system acts with different penetrating inks and can also present different colors. The difference of hue is mainly that the first material powder is taken as an example, the permeation ink 1 presents iron red, and iron ions in the permeation ink 1 react in situ in an oxidizing atmosphere to form ferric oxide, and amorphous SiO in the first material powder 2 Wrapping the surface of the ferric oxide to stabilize the color development of the ferric oxide and form iron red; the permeated ink 2 is yellow, and the chromium ions in the permeated ink 2 react with titanium oxide in the first material powder in situ to form chromium-titanium solid solution, so that the permeated ink is yellow; the penetrating ink 3 presents a blue color, and the cobalt ions in the penetrating ink 3 react with the aluminum oxide and the zinc oxide in the first material powder in situ to form cobalt-aluminum-zinc solid solution, so that the blue color is presented; the iron ions and cobalt ions in the penetrating ink 4 react in situ to form an iron-cobalt solid solution, and the iron-cobalt solid solution is black; the penetration ink 5 presents yellowish color, because a small amount of chromium ions in the penetration ink 5 reacts with titanium oxide in the first material powder in situ to form a small amount of chromium-titanium solid solution, the penetration ink presents yellowish color; the penetrating ink 6 is yellow-green, because a large amount of chromium ions are contained in the penetrating ink 6, a part of chromium ions react with titanium oxide in the first material powder in situ to form a chromium-titanium solid solution, the solution is yellow, and excessive chromium ions react in situ in an oxidizing atmosphere to form green chromium oxide, so that the composite color development, namely yellow-green, is finally formed; the penetrating ink 7 is pink, mainly because the grain diameter of gold colloid in the penetrating ink 7 is about 40nm Light of 530nm wavelength has the maximum absorption capacity to appear pink.
The same penetrating ink can also present the same color in green body powder materials of different systems, but the saturation of the color is different. That is, the same color of the same penetrating ink is developed by the powder materials with different materials, but the saturation of the color is different. Saturation refers to the purity of a color, i.e., the degree to which reflected or transmitted light approaches spectral colors, also known as purity or chroma. The saturation of the color depends on the ability of the green body powder surface to selectively reflect spectral radiation. The green powder has high reflectivity in a certain narrow band of the spectrum, and low or no reflectivity in other wavelengths, which indicates that the green powder has high selective reflection capability, so that the saturation of the color is higher, and vice versa. In order to more intuitively compare the differences of the same hue and different saturation, the CIE standard chromaticity system, namely CIE 1976L a b color space, is adopted as an international color measurement standard in the practical application process of the application. Wherein L represents the brightness of the color (0 is black, 100 is white), chromaticity a is a position (-100) between green and red, and chromaticity b represents a position (-100) between blue and yellow. Taking the penetrating ink 1 as an example, the first material powder, the second material powder and the fourth material powder respectively act with the penetrating ink 1, and are all in iron red, but have different color saturation, and are specifically shown in table 1.
TABLE 1 color values of powders of different materials after the effect of penetrating ink 1
First material powder Second material powder Fourth materialPowder material
L 46~46.5 45.5~46 46.5~47
a 15.5~17.5 13.5~15.5 17.5~20
b 13~14 12~13 14~15
It is clear from table 1 that for the color development of the penetrating ink 1 on the green body powder, the color saturation is ordered from high to low: the fourth material powder is larger than the first material powder and larger than the second material powder.
Further, the weight ratio of hydrofluoric acid to benzoic acid to hydrochloric acid in the weathering functional agent in the step I is 1-5:5-20:75-94.
The beneficial effects obtained by the invention are as follows: four material powders are developed, the whole stone texture is formed through a digital whole material distribution system, a permeation ink-jet ink set is developed, the problems that exposed base textures, colors and surface contrasts are large, the decoration effect is inconsistent and the exposed bottom is not attractive in later deep processing of ceramic tiles such as edging, slotting and chamfering are well solved by utilizing the differences of color development hues of the same material powder to different permeation inks, the differences of color development hues of different material powder to the same permeation ink, and the color saturation of different material powder to the same permeation ink. Meanwhile, the special textures formed by long-term natural environment weathering of natural stone can be presented by spraying the weathering-imitating functional reagent on the surface of the porcelain tile with the weathering stone textures after edging and polishing.
Drawings
FIG. 1 is a schematic view of a full body distribution apparatus;
wherein, 1-frame, 2-first transmission belt, 3-line forming system, 4-powder supplementing system, 5-particle forming system, 4-1-strickling hopper, 4-2-fourth transmission belt, 4-3-powder supplementing hopper, 5-1-particle powder distributing hopper, 5-2-fifth transmission belt, 5-3-pressing device, 5-4-strickling, 5-screen, 6-thick line forming system, 7-medium line forming system, 8-thin line forming system, 6-1-thick line distributing hopper, 6-2-first transmission belt, 6-3-second transmission belt, 7-1-medium line distributing hopper, 7-2-third transmission belt, 7-3-powder scraping hopper, 7-4-engraving belt, 8-1-thin line distributing hopper, 8-2-inclined baffle.
FIG. 2 is a top view of a thick line formation system and a medium line formation system;
wherein 6-1-coarse line material distribution hopper, 6-2-first branch transmission belt, 6-3-second branch transmission belt, 7-1-medium line material distribution hopper, 7-2-third branch transmission belt, 7-3-powder scraping hopper and 7-4-engraving belt.
Detailed Description
The invention will be described in detail below with reference to the drawings in combination with embodiments.
Example 1
As shown in fig. 1-2, the invention is realized by the following steps:
A. preparing a green body powder group for the porcelain tile with the weathered stone texture according to a conventional method, wherein the green body powder group consists of four green body powder with different chemical compositions: a first material powder, a second material powder, a third material powder and a fourth material powder; wherein the chemical composition of the first material powder is as followsThe weight percentages are as follows: siO (SiO) 2 66%，Al 2 O 3 20%，CaO 3%，MgO 0.5%，K 2 O 2.5%，Na 2 O 2%，ZnO 1%，Fe 2 O 3 ≤1%，TiO 2 Less than or equal to 0.3 percent and IL less than or equal to 5 percent, wherein the chemical composition of the second material powder is as follows by weight percent: siO (SiO) 2 68%，Al 2 O 3 19%，CaO 0.5%，MgO 11%，K 2 O 1.5%，Na 2 O 1%，ZnO 1%，Fe 2 O 3 ≤0.7%，TiO 2 Less than or equal to 0.2 percent and less than or equal to 5 percent of IL, wherein the chemical composition of the third material powder is as follows by weight percent: siO (SiO) 2 71%，Al 2 O 3 5%，CaO 21%，MgO 0.5%，K 2 O 0.15%，Na 2 O 0.15%，SnO 2 1.5%，Fe 2 O 3 ≤1%，TiO 2 Less than or equal to 0.5 percent and IL less than or equal to 3 percent, and the chemical composition of the fourth material powder is as follows by weight percent: siO (SiO) 2 69%，Al 2 O 3 15%，CaO 1.3%，MgO 0.5%，K 2 O 4%，Na 2 O 5%，ZnO 1%，Fe 2 O 3 ≤1%，TiO 2 Less than or equal to 0.5 percent and IL less than or equal to 5 percent for standby; the first material powder, the second material powder and the fourth material powder all contain 8% of amorphous silicon dioxide;
B. cloth: d, adopting a digital whole body distribution system to distribute the green body powder group for the porcelain tile with the weathered stone texture, so as to form a whole body green body powder layer;
The adopted digital whole body distribution system comprises an intelligent software control system and a whole body distribution device; the whole-body distributing device comprises a frame 1, a first transmission belt 2, a line forming system 3, a powder supplementing system 4 and a particle forming system 5; the line forming system 3 comprises a thick line forming system 6, a medium line forming system 7 and a thin line forming system 8; the thick line forming system 6 comprises a thick line distributing hopper 6-1 positioned at the starting end of the advancing direction of the first conveying belt 2, a first sub-conveying belt 6-2 positioned below the thick line distributing hopper 6-1 and a second sub-conveying belt 6-3 positioned below the first sub-conveying belt 6-2; the medium line forming system 7 comprises an engraving belt 7-4 at the front end of the second sub-conveying belt 6-3 along the advancing direction of the first conveying belt 2, a powder scraping hopper 4-3 closely attached to the surface of the engraving belt 7-4, a third sub-conveying belt 7-2 positioned above the powder scraping hopper 4-3 and a medium line material distributing hopper 7-1 positioned above the third sub-conveying belt 7-2; the fine wire forming system 8 comprises an inclined baffle plate 8-2 at the front end of the third sub-conveying belt 7-2 along the advancing direction of the first conveying belt 2 and a fine wire distribution hopper 8-1 above the inclined baffle plate 8-2; the powder supplementing system 4 comprises a scraping hopper 4-1, a fourth-division conveying belt 4-2 and a powder supplementing hopper 4-3, wherein the scraping hopper 4-1 is used for inclining the front end of the baffle plate 8-2 along the advancing direction of the first conveying belt 2, and the fourth-division conveying belt 4-2 is arranged above the scraping hopper 4-1; the particle forming system 5 comprises a screen 5-5 at the front end of a fourth sub-conveyor belt 4-2 along the advancing direction of the first conveyor belt 2, a scraping belt 5-4 closely attached to the screen 5-5, and a fifth sub-conveyor belt 5-2 above the scraping belt 5-4 along the advancing direction of the first conveyor belt 2, wherein a jacking device 5-3 and a particle powder material distributing hopper 5-1 are sequentially distributed on the fifth sub-conveyor belt 5-2; the width of the thick line forming system 6 and the medium line forming system 7 in the direction perpendicular to the first conveyor belt 2 is smaller than the first conveyor belt 2;
The working process is as follows: firstly, inputting a digital fossil texture pattern through an intelligent software control system, driving a whole body distributing device to distribute according to the digital fossil texture pattern, then sequentially blanking a coarse line distributing hopper 6-1 in the whole body distributing device, forming a powder layer on a first sub-conveying belt 6-2, enabling the powder layer to fall onto a second sub-conveying belt 6-3 along with the transmission of the first sub-conveying belt 6-2, blanking the second sub-conveying belt 6-3 along with swinging motion perpendicular to the advancing direction of the first conveying belt 2, throwing powder onto the first conveying belt 2, enabling the powder on the first conveying belt 2 to be distributed in an irregular arc shape due to the fact that the first conveying belt 2 always moves along the advancing direction, forming arc-shaped coarse lines on the first conveying belt 2, when the first conveying belt 2 carrying the coarse-line powder moves to the lower part of the medium-line forming system 7, the medium-line distributing hopper 7-1 starts to feed, a powder material layer is formed on the third conveying belt 7-2 in a lamination feeding mode, the powder material layer falls into the powder scraping hopper 7-3 along with the movement of the third conveying belt 7-2, the powder material in the concave part of the engraving belt 7-4 is conveyed to the gap of the coarse-line powder material on the first conveying belt 2 by the engraving belt 7-4 through the interaction of the powder scraping hopper 7-3 and the engraving belt 7-4, the powder scraping hopper 7-3 and the engraving belt 7-4 do swinging motion along the direction perpendicular to the advancing direction of the first conveying belt 2 in the feeding process, irregular arc-shaped distribution is formed on the first conveying belt 2, because the carving belt 7-4 is designed into a concave stripe with a certain width, the width of arc powder formed by powder in the concave position on the first conveying belt 2 is smaller than that of arc powder formed by the thick line distribution system 6, when the first conveying belt 2 carrying the thick line powder layer and the medium line powder layer moves below the thin line forming system 8, the thin line distribution hopper 8-1 starts to intermittently feed, the powder falls onto the inclined baffle 8-2 and then slides to the gap between the thick line powder layer and the medium line powder layer on the first conveying belt 2, after that, when the first conveying belt 2 carrying the thick line powder layer, the medium line powder layer and the thin line powder layer moves below the powder supplementing system 4, the powder supplementing hopper 4-3 starts to feed, sequentially falling onto a fourth conveying belt 4-2 to form a laminated powder layer, then falling onto a strickling hopper 4-1, applying powder supplement to gaps among the coarse powder layer, the medium powder layer and the fine powder layer on the first conveying belt 2 through the strickling hopper 4-1 to finish powder supplement operation, then conveying the powder layer after finishing powder supplement operation to the lower part of a particle forming system 5 by the first conveying belt 2, starting to feed the particle powder material hopper 5-1, falling onto a fifth conveying belt 5-2, then conveying powder to a jacking device 5-3 by the fifth conveying belt 5-2, starting to work by the jacking device 5-3, pre-pressing the powder to form powder blocks with a certain compactness degree, moving along with the fifth conveying belt 5-2, falling onto a screen 5-5 with a scraping belt 5-4, then, the scraping sheet 5-4 moves back and forth along the direction perpendicular to the movement direction of the first conveying belt 2, powder blocks are extruded through the screen 5-5, particles with the same pore size as the screen 5-5 are formed through extrusion of the screen 5-5, the particles fall onto the powder layer with powder supplement completion on the first conveying belt 2, and due to the fact that the particles have certain weight, the screen 5-5 and the first conveying belt 2 have certain height difference, the particles are embedded into the powder layer with powder supplement completion under the action of gravity to form a final blank powder layer with certain texture, and then the blank powder layer with certain texture is sent into a press die cavity through the first conveying belt 2 to be subjected to back pressure molding;
C. And (3) forming: pushing the powder layer of the whole body blank body formed by the cloth in the step B into a die cavity, and pressing and forming to form a porcelain tile blank body with weathered stone textures;
D. drying the green body: c, drying the ceramic tile blank body with the weathered stone texture formed in the step C according to a conventional method;
E. texture recognition: d, identifying the texture of the dried green body in the step D by adopting a texture collector, and sending a network signal to a digital ink-jet printer;
F. inkjet decoration: preparing a penetrating inkjet ink set, including penetrating ink 1, penetrating ink 2, penetrating ink 3, penetrating ink 4, penetrating ink 5, penetrating ink 6 and penetrating ink 7; the penetrating ink 1 is a composition for coloring by iron ions, the penetrating ink 2 is a composition for coloring by chromium ions and titanium ions, the penetrating ink 3 is a composition for coloring by cobalt ions, the penetrating ink 4 is a composition for coloring by iron ions and cobalt ions, the penetrating ink 5 is a composition for coloring by chromium ions and tin ions, the penetrating ink 6 is a composition for coloring by chromium ions, and the penetrating ink 7 is a composition for coloring by gold ions; the digital ink-jet printer receives the network signal sent by the texture collector in the step E, and then calls out an ink-jet pattern of the corresponding stone texture, and then the penetrating ink-jet ink group is aligned and jet-printed on the surface of the porcelain tile blank body with the weathered stone texture after the texture identification in the step E according to the ink-jet pattern of the corresponding stone texture;
G. Firing: f, placing the ceramic tile blank with the weathered stone texture after the ink-jet decoration in the step F into a roller kiln for firing, wherein the firing temperature is 1200 ℃, and the firing period is 110 minutes, so as to obtain a ceramic tile sintered body with the weathered stone texture;
H. edging and polishing: performing edging and polishing treatment on the ceramic tile sintered body with the weathered stone texture obtained by sintering in the step G by using conventional edging and polishing processing equipment to obtain a semi-finished product of the ceramic tile with the weathered stone texture;
I. and (3) treating the simulated weathering effect: and preparing the weathering-simulating functional reagent, wherein the weight ratio of hydrofluoric acid to benzoic acid to hydrochloric acid in the weathering-simulating functional reagent is 1:20:79. And (3) spraying the weathering simulation functional reagent on the surface of the porcelain tile semi-finished product with the weathering stone texture after edging and polishing in the step (H) to obtain the porcelain tile finished product with the weathering stone texture.
Example 2
As shown in fig. 1-2, the invention is realized by the following steps:
A. preparing a green body powder group for the porcelain tile with the weathered stone texture according to a conventional method, wherein the green body powder group consists of four green body powder with different chemical compositions: a first material powder, a second material powder, a third material powder and a fourth material powder; wherein the chemical composition of the first material powder is as follows by weight percent: siO (SiO) 2 65%，Al 2 O 3 22%，CaO 2.5%，MgO 1%，K 2 O 2%，Na 2 O 2.5%，ZnO 0.1%，Fe 2 O 3 ≤1%，TiO 2 Less than or equal to 0.3 percent and IL less than or equal to 5 percent, wherein the chemical composition of the second material powder is as follows by weight percent: siO (SiO) 2 70%，Al 2 O 3 17%，CaO1%，MgO 9%，K 2 O 2%，Na 2 O 0.5%，ZnO 0.1%，Fe 2 O 3 ≤0.7%，TiO 2 Less than or equal to 0.2 percent and less than or equal to 5 percent of IL, wherein the chemical composition of the third material powder is as follows by weight percent: siO (SiO) 2 68%%，Al 2 O 3 7%，CaO 18%，MgO 1%，K 2 O 0.1%，Na 2 O 0.3%，SnO 2 0.5%，Fe 2 O 3 ≤1%，TiO 2 Less than or equal to 0.5 percent and IL less than or equal to 3 percent, and the chemical composition of the fourth material powder is as follows by weight percent: siO (SiO) 2 71%，Al 2 O 3 13%，CaO 2%，MgO 0.1%，K 2 O 5%，Na 2 O 4%，ZnO 0.1%，Fe 2 O 3 ≤1%，TiO 2 Less than or equal to 0.5 percent and IL less than or equal to 5 percent for standby; the first material powder, the second material powder and the fourth material powder all contain 1 percent of amorphous dioxideSilicon;
B. cloth: d, adopting a digital whole body distribution system to distribute the green body powder group for the porcelain tile with the weathered stone texture, so as to form a whole body green body powder layer;
the adopted digital whole body distribution system comprises an intelligent software control system and a whole body distribution device; the whole-body distributing device comprises a frame 1, a first transmission belt 2, a line forming system 3, a powder supplementing system 4 and a particle forming system 5; the line forming system 3 comprises a thick line forming system 6, a medium line forming system 7 and a thin line forming system 8; the thick line forming system 6 comprises a thick line distributing hopper 6-1 positioned at the starting end of the advancing direction of the first conveying belt 2, a first sub-conveying belt 6-2 positioned below the thick line distributing hopper 6-1 and a second sub-conveying belt 6-3 positioned below the first sub-conveying belt 6-2; the medium line forming system 7 comprises an engraving belt 7-4 at the front end of the second sub-conveying belt 6-3 along the advancing direction of the first conveying belt 2, a powder scraping hopper 4-3 closely attached to the surface of the engraving belt 7-4, a third sub-conveying belt 7-2 positioned above the powder scraping hopper 4-3 and a medium line material distributing hopper 7-1 positioned above the third sub-conveying belt 7-2; the fine wire forming system 8 comprises an inclined baffle plate 8-2 at the front end of the third sub-conveying belt 7-2 along the advancing direction of the first conveying belt 2 and a fine wire distribution hopper 8-1 above the inclined baffle plate 8-2; the powder supplementing system 4 comprises a scraping hopper 4-1, a fourth-division conveying belt 4-2 and a powder supplementing hopper 4-3, wherein the scraping hopper 4-1 is used for inclining the front end of the baffle plate 8-2 along the advancing direction of the first conveying belt 2, and the fourth-division conveying belt 4-2 is arranged above the scraping hopper 4-1; the particle forming system 5 comprises a screen 5-5 at the front end of a fourth sub-conveyor belt 4-2 along the advancing direction of the first conveyor belt 2, a scraping belt 5-4 closely attached to the screen 5-5, and a fifth sub-conveyor belt 5-2 above the scraping belt 5-4 along the advancing direction of the first conveyor belt 2, wherein a jacking device 5-3 and a particle powder material distributing hopper 5-1 are sequentially distributed on the fifth sub-conveyor belt 5-2; the width of the thick line forming system 6 and the medium line forming system 7 in the direction perpendicular to the first conveyor belt 2 is smaller than the first conveyor belt 2;
The working process is as follows: firstly, inputting a digital fossil texture pattern through an intelligent software control system, driving a whole body distributing device to distribute according to the digital fossil texture pattern, then sequentially blanking a coarse line distributing hopper 6-1 in the whole body distributing device, forming a powder layer on a first sub-conveying belt 6-2, enabling the powder layer to fall onto a second sub-conveying belt 6-3 along with the transmission of the first sub-conveying belt 6-2, blanking the second sub-conveying belt 6-3 along with swinging motion perpendicular to the advancing direction of the first conveying belt 2, throwing powder onto the first conveying belt 2, enabling the powder on the first conveying belt 2 to be distributed in an irregular arc shape due to the fact that the first conveying belt 2 always moves along the advancing direction, forming arc-shaped coarse lines on the first conveying belt 2, when the first conveying belt 2 carrying the coarse-line powder moves to the lower part of the medium-line forming system 7, the medium-line distributing hopper 7-1 starts to feed, a powder material layer is formed on the third conveying belt 7-2 in a lamination feeding mode, the powder material layer falls into the powder scraping hopper 7-3 along with the movement of the third conveying belt 7-2, the powder material in the concave part of the engraving belt 7-4 is conveyed to the gap of the coarse-line powder material on the first conveying belt 2 by the engraving belt 7-4 through the interaction of the powder scraping hopper 7-3 and the engraving belt 7-4, the powder scraping hopper 7-3 and the engraving belt 7-4 do swinging motion along the direction perpendicular to the advancing direction of the first conveying belt 2 in the feeding process, irregular arc-shaped distribution is formed on the first conveying belt 2, because the carving belt 7-4 is designed into a concave stripe with a certain width, the width of arc powder formed by powder in the concave position on the first conveying belt 2 is smaller than that of arc powder formed by the thick line distribution system 6, when the first conveying belt 2 carrying the thick line powder layer and the medium line powder layer moves below the thin line forming system 8, the thin line distribution hopper 8-1 starts to intermittently feed, the powder falls onto the inclined baffle 8-2 and then slides to the gap between the thick line powder layer and the medium line powder layer on the first conveying belt 2, after that, when the first conveying belt 2 carrying the thick line powder layer, the medium line powder layer and the thin line powder layer moves below the powder supplementing system 4, the powder supplementing hopper 4-3 starts to feed, sequentially falling onto a fourth conveying belt 4-2 to form a laminated powder layer, then falling onto a strickling hopper 4-1, applying powder supplement to gaps among the coarse powder layer, the medium powder layer and the fine powder layer on the first conveying belt 2 through the strickling hopper 4-1 to finish powder supplement operation, then conveying the powder layer after finishing powder supplement operation to the lower part of a particle forming system 5 by the first conveying belt 2, starting to feed the particle powder material hopper 5-1, falling onto a fifth conveying belt 5-2, then conveying powder to a jacking device 5-3 by the fifth conveying belt 5-2, starting to work by the jacking device 5-3, pre-pressing the powder to form powder blocks with a certain compactness degree, moving along with the fifth conveying belt 5-2, falling onto a screen 5-5 with a scraping belt 5-4, then, the scraping sheet 5-4 moves back and forth along the direction perpendicular to the movement direction of the first conveying belt 2, powder blocks are extruded through the screen 5-5, particles with the same pore size as the screen 5-5 are formed through extrusion of the screen 5-5, the particles fall onto the powder layer with powder supplement completion on the first conveying belt 2, and due to the fact that the particles have certain weight, the screen 5-5 and the first conveying belt 2 have certain height difference, the particles are embedded into the powder layer with powder supplement completion under the action of gravity to form a final blank powder layer with certain texture, and then the blank powder layer with certain texture is sent into a press die cavity through the first conveying belt 2 to be subjected to back pressure molding;
C. And (3) forming: pushing the powder layer of the whole body blank body formed by the cloth in the step B into a die cavity, and pressing and forming to form a porcelain tile blank body with weathered stone textures;
D. drying the green body: c, drying the ceramic tile blank body with the weathered stone texture formed in the step C according to a conventional method;
E. texture recognition: d, identifying the texture of the dried green body in the step D by adopting a texture collector, and sending a network signal to a digital ink-jet printer;
F. inkjet decoration: preparing a penetrating inkjet ink set, including penetrating ink 1, penetrating ink 2, penetrating ink 3, penetrating ink 4, penetrating ink 5, penetrating ink 6 and penetrating ink 7; the penetrating ink 1 is a composition for coloring by iron ions, the penetrating ink 2 is a composition for coloring by chromium ions and titanium ions, the penetrating ink 3 is a composition for coloring by cobalt ions, the penetrating ink 4 is a composition for coloring by iron ions and cobalt ions, the penetrating ink 5 is a composition for coloring by chromium ions and tin ions, the penetrating ink 6 is a composition for coloring by chromium ions, and the penetrating ink 7 is a composition for coloring by gold ions; the digital ink-jet printer receives the network signal sent by the texture collector in the step E, and then calls out an ink-jet pattern of the corresponding stone texture, and then the penetrating ink-jet ink group is aligned and jet-printed on the surface of the porcelain tile blank body with the weathered stone texture after the texture identification in the step E according to the ink-jet pattern of the corresponding stone texture;
G. Firing: f, placing the ceramic tile blank with the weathered stone texture after the ink-jet decoration in the step F into a roller kiln for firing, wherein the firing temperature is 1150 ℃, and the firing period is 150 minutes, so as to obtain a ceramic tile sintered body with the weathered stone texture;
H. edging and polishing: performing edging and polishing treatment on the ceramic tile sintered body with the weathered stone texture obtained by sintering in the step G by using conventional edging and polishing processing equipment to obtain a semi-finished product of the ceramic tile with the weathered stone texture;
I. and (3) treating the simulated weathering effect: and preparing the weathering-simulating functional reagent, wherein the weight ratio of hydrofluoric acid to benzoic acid to hydrochloric acid in the weathering-simulating functional reagent is 5:5:90. And (3) spraying the weathering simulation functional reagent on the surface of the porcelain tile semi-finished product with the weathering stone texture after edging and polishing in the step (H) to obtain the porcelain tile finished product with the weathering stone texture.
Example 3
As shown in fig. 1-2, the invention is realized by the following steps:
A. preparing a green body powder group for the porcelain tile with the weathered stone texture according to a conventional method, wherein the green body powder group consists of four green body powder with different chemical compositions: a first material powder, a second material powder, a third material powder and a fourth material powder; wherein the chemical composition of the first material powder is as follows by weight percent: siO (SiO) 2 68%，Al 2 O 3 18%，CaO 3.5%，MgO 0.1%，K 2 O 3%，Na 2 O 1.5%，ZnO 0.5%，Fe 2 O 3 ≤1%，TiO 2 ≤0.3%，IL is less than or equal to 5 percent, and the chemical composition of the second material powder is as follows by weight percent: siO (SiO) 2 67%%，Al 2 O 3 20%，CaO 0.1%，MgO 13%，K 2 O 1%，Na 2 O 1.5%，ZnO 0.5%，Fe 2 O 3 ≤0.7%，TiO 2 Less than or equal to 0.2 percent and less than or equal to 5 percent of IL, wherein the chemical composition of the third material powder is as follows by weight percent: siO (SiO) 2 73%，Al 2 O 3 3%，CaO 23%，MgO 0.1%，K 2 O 0.3%，Na 2 O 0.1%，SnO 2 2%，Fe 2 O 3 ≤1%，TiO 2 Less than or equal to 0.5 percent and IL less than or equal to 3 percent, and the chemical composition of the fourth material powder is as follows by weight percent: siO (SiO) 2 68%%，Al 2 O 3 17%，CaO 0.5%，MgO 1%，K 2 O 3%，Na 2 O 6%，ZnO 0.5%，Fe 2 O 3 ≤1%，TiO 2 Less than or equal to 0.5 percent and IL less than or equal to 5 percent for standby; the first material powder, the second material powder and the fourth material powder all contain 5% of amorphous silicon dioxide;
B. cloth: d, adopting a digital whole body distribution system to distribute the green body powder group for the porcelain tile with the weathered stone texture, so as to form a whole body green body powder layer;
the adopted digital whole body distribution system comprises an intelligent software control system and a whole body distribution device; the whole-body distributing device comprises a frame 1, a first transmission belt 2, a line forming system 3, a powder supplementing system 4 and a particle forming system 5; the line forming system 3 comprises a thick line forming system 6, a medium line forming system 7 and a thin line forming system 8; the thick line forming system 6 comprises a thick line distributing hopper 6-1 positioned at the starting end of the advancing direction of the first conveying belt 2, a first sub-conveying belt 6-2 positioned below the thick line distributing hopper 6-1 and a second sub-conveying belt 6-3 positioned below the first sub-conveying belt 6-2; the medium line forming system 7 comprises an engraving belt 7-4 at the front end of the second sub-conveying belt 6-3 along the advancing direction of the first conveying belt 2, a powder scraping hopper 4-3 closely attached to the surface of the engraving belt 7-4, a third sub-conveying belt 7-2 positioned above the powder scraping hopper 4-3 and a medium line material distributing hopper 7-1 positioned above the third sub-conveying belt 7-2; the fine wire forming system 8 comprises an inclined baffle plate 8-2 at the front end of the third sub-conveying belt 7-2 along the advancing direction of the first conveying belt 2 and a fine wire distribution hopper 8-1 above the inclined baffle plate 8-2; the powder supplementing system 4 comprises a scraping hopper 4-1, a fourth-division conveying belt 4-2 and a powder supplementing hopper 4-3, wherein the scraping hopper 4-1 is used for inclining the front end of the baffle plate 8-2 along the advancing direction of the first conveying belt 2, and the fourth-division conveying belt 4-2 is arranged above the scraping hopper 4-1; the particle forming system 5 comprises a screen 5-5 at the front end of a fourth sub-conveyor belt 4-2 along the advancing direction of the first conveyor belt 2, a scraping belt 5-4 closely attached to the screen 5-5, and a fifth sub-conveyor belt 5-2 above the scraping belt 5-4 along the advancing direction of the first conveyor belt 2, wherein a jacking device 5-3 and a particle powder material distributing hopper 5-1 are sequentially distributed on the fifth sub-conveyor belt 5-2; the width of the thick line forming system 6 and the medium line forming system 7 in the direction perpendicular to the first conveyor belt 2 is smaller than the first conveyor belt 2;
The working process is as follows: firstly, inputting a digital fossil texture pattern through an intelligent software control system, driving a whole body distributing device to distribute according to the digital fossil texture pattern, then sequentially blanking a coarse line distributing hopper 6-1 in the whole body distributing device, forming a powder layer on a first sub-conveying belt 6-2, enabling the powder layer to fall onto a second sub-conveying belt 6-3 along with the transmission of the first sub-conveying belt 6-2, blanking the second sub-conveying belt 6-3 along with swinging motion perpendicular to the advancing direction of the first conveying belt 2, throwing powder onto the first conveying belt 2, enabling the powder on the first conveying belt 2 to be distributed in an irregular arc shape due to the fact that the first conveying belt 2 always moves along the advancing direction, forming arc-shaped coarse lines on the first conveying belt 2, when the first conveying belt 2 carrying the coarse-line powder moves to the lower part of the medium-line forming system 7, the medium-line distributing hopper 7-1 starts to feed, a powder material layer is formed on the third conveying belt 7-2 in a lamination feeding mode, the powder material layer falls into the powder scraping hopper 7-3 along with the movement of the third conveying belt 7-2, the powder material in the concave part of the engraving belt 7-4 is conveyed to the gap of the coarse-line powder material on the first conveying belt 2 by the engraving belt 7-4 through the interaction of the powder scraping hopper 7-3 and the engraving belt 7-4, the powder scraping hopper 7-3 and the engraving belt 7-4 do swinging motion along the direction perpendicular to the advancing direction of the first conveying belt 2 in the feeding process, irregular arc-shaped distribution is formed on the first conveying belt 2, because the carving belt 7-4 is designed into a concave stripe with a certain width, the width of arc powder formed by powder in the concave position on the first conveying belt 2 is smaller than that of arc powder formed by the thick line distribution system 6, when the first conveying belt 2 carrying the thick line powder layer and the medium line powder layer moves below the thin line forming system 8, the thin line distribution hopper 8-1 starts to intermittently feed, the powder falls onto the inclined baffle 8-2 and then slides to the gap between the thick line powder layer and the medium line powder layer on the first conveying belt 2, after that, when the first conveying belt 2 carrying the thick line powder layer, the medium line powder layer and the thin line powder layer moves below the powder supplementing system 4, the powder supplementing hopper 4-3 starts to feed, sequentially falling onto a fourth conveying belt 4-2 to form a laminated powder layer, then falling onto a strickling hopper 4-1, applying powder supplement to gaps among the coarse powder layer, the medium powder layer and the fine powder layer on the first conveying belt 2 through the strickling hopper 4-1 to finish powder supplement operation, then conveying the powder layer after finishing powder supplement operation to the lower part of a particle forming system 5 by the first conveying belt 2, starting to feed the particle powder material hopper 5-1, falling onto a fifth conveying belt 5-2, then conveying powder to a jacking device 5-3 by the fifth conveying belt 5-2, starting to work by the jacking device 5-3, pre-pressing the powder to form powder blocks with a certain compactness degree, moving along with the fifth conveying belt 5-2, falling onto a screen 5-5 with a scraping belt 5-4, then, the scraping sheet 5-4 moves back and forth along the direction perpendicular to the movement direction of the first conveying belt 2, powder blocks are extruded through the screen 5-5, particles with the same pore size as the screen 5-5 are formed through extrusion of the screen 5-5, the particles fall onto the powder layer with powder supplement completion on the first conveying belt 2, and due to the fact that the particles have certain weight, the screen 5-5 and the first conveying belt 2 have certain height difference, the particles are embedded into the powder layer with powder supplement completion under the action of gravity to form a final blank powder layer with certain texture, and then the blank powder layer with certain texture is sent into a press die cavity through the first conveying belt 2 to be subjected to back pressure molding;
C. And (3) forming: pushing the powder layer of the whole body blank body formed by the cloth in the step B into a die cavity, and pressing and forming to form a porcelain tile blank body with weathered stone textures;
D. drying the green body: c, drying the ceramic tile blank body with the weathered stone texture formed in the step C according to a conventional method;
E. texture recognition: d, identifying the texture of the dried green body in the step D by adopting a texture collector, and sending a network signal to a digital ink-jet printer;
F. inkjet decoration: preparing a penetrating inkjet ink set, including penetrating ink 1, penetrating ink 2, penetrating ink 3, penetrating ink 4, penetrating ink 5, penetrating ink 6 and penetrating ink 7; the penetrating ink 1 is a composition for coloring by iron ions, the penetrating ink 2 is a composition for coloring by chromium ions and titanium ions, the penetrating ink 3 is a composition for coloring by cobalt ions, the penetrating ink 4 is a composition for coloring by iron ions and cobalt ions, the penetrating ink 5 is a composition for coloring by chromium ions and tin ions, the penetrating ink 6 is a composition for coloring by chromium ions, and the penetrating ink 7 is a composition for coloring by gold ions; the digital ink-jet printer receives the network signal sent by the texture collector in the step E, and then calls out an ink-jet pattern of the corresponding stone texture, and then the penetrating ink-jet ink group is aligned and jet-printed on the surface of the porcelain tile blank body with the weathered stone texture after the texture identification in the step E according to the ink-jet pattern of the corresponding stone texture;
G. Firing: f, placing the ceramic tile blank with the weathered stone texture after the ink-jet decoration in the step F into a roller kiln for firing, wherein the firing temperature is 1250 ℃, and the firing period is 60 minutes, so as to obtain a ceramic tile sintered body with the weathered stone texture;
H. edging and polishing: performing edging and polishing treatment on the ceramic tile sintered body with the weathered stone texture obtained by sintering in the step G by using conventional edging and polishing processing equipment to obtain a semi-finished product of the ceramic tile with the weathered stone texture;
I. and (3) treating the simulated weathering effect: and preparing the weathering-simulating functional reagent, wherein the weight ratio of hydrofluoric acid to benzoic acid to hydrochloric acid in the weathering-simulating functional reagent is 5:20:75. And (3) spraying the weathering simulation functional reagent on the surface of the porcelain tile semi-finished product with the weathering stone texture after edging and polishing in the step (H) to obtain the porcelain tile finished product with the weathering stone texture.
The above embodiments are only for illustrating the technical aspects of the present invention and not for limiting the same, although the present invention has been described in detail with reference to the preferred embodiments, and it will be understood by those skilled in the art. Modifications and equivalent substitutions can be made to the specific embodiments of the present invention or to some of the technical features without departing from the spirit of the technical solution of the present invention, and they should be covered in the scope of the technical solution claimed in the present invention.

Claims (7)

1. The production method of the porcelain tile with the weathered stone texture is characterized by comprising the following steps of:
A. preparing a green body powder group for the porcelain tile with the weathered stone texture according to a conventional method, wherein the green body powder group consists of four green body powders with different chemical compositions: a first material powder, a second material powder, a third material powder and a fourth material powder; wherein the chemical composition of the first material powder is as follows by weight percent: siO (SiO) 2 65％～68％，Al 2 O 3 18～22％，CaO 2.5～3.5％，MgO 0.1～1％，K 2 O 2～3％，Na 2 O1.5～2.5％，ZnO 0.1％～1％，Fe 2 O 3 ≤1％，TiO 2 Less than or equal to 0.3 percent and IL less than or equal to 5 percent, wherein the chemical composition of the second material powder is as follows by weight percent: siO (SiO) 2 67％～70％，Al 2 O 3 17～20％，CaO 0～1％，MgO 9～13％，K 2 O 1～2％，Na 2 O 0.5～1.5％，ZnO 0.1％～1％，Fe 2 O 3 ≤0.7％，TiO 2 Less than or equal to 0.2 percent and less than or equal to 5 percent of IL, wherein the chemical composition of the third material powder is as follows by weight percent: siO (SiO) 2 68％～73％，Al 2 O 3 3～7％，CaO 18～23％，MgO 0.1～1％，K 2 O 0～0.3％，Na 2 O 0～0.3％，Fe 2 O 3 ≤1％，TiO 2 Less than or equal to 0.5 percent and IL less than or equal to 3 percent, and the chemical composition of the fourth material powder is as follows by weight percent: siO (SiO) 2 68％～71％，Al 2 O 3 13～17％，CaO 0.5～2％，MgO 0.1～1％，K 2 O 3～5％，Na 2 O 4～6％，ZnO 0.1％～1％，Fe 2 O 3 ≤1％，TiO 2 Less than or equal to 0.5 percent and IL less than or equal to 5 percent for standby;
B. cloth: d, adopting a digital whole body distribution system to distribute the green body powder group for the porcelain tile with the weathered stone texture, so as to form a whole body green body powder layer;
C. and (3) forming: pushing the powder layer of the whole body blank body formed by the cloth in the step B into a die cavity, and pressing and forming to form a porcelain tile blank body with weathered stone textures;
D. Drying the green body: c, drying the ceramic tile blank body with the weathered stone texture formed in the step C according to a conventional method;
E. texture recognition: d, identifying the texture of the dried green body in the step D by adopting a texture collector, and sending a network signal to a digital ink-jet printer;
F. inkjet decoration: preparing a penetrating inkjet ink set, including penetrating ink 1, penetrating ink 2, penetrating ink 3, penetrating ink 4, penetrating ink 5, penetrating ink 6 and penetrating ink 7; the penetrating ink 1 is a composition for coloring by iron ions, the penetrating ink 2 is a composition for coloring by chromium ions and titanium ions, the penetrating ink 3 is a composition for coloring by cobalt ions, the penetrating ink 4 is a composition for coloring by iron ions and cobalt ions, the penetrating ink 5 is a composition for coloring by chromium ions and tin ions, the penetrating ink 6 is a composition for coloring by chromium ions, and the penetrating ink 7 is a composition for coloring by gold ions; the digital ink-jet printer receives the network signal sent by the texture collector in the step E, and then calls out an ink-jet pattern of the corresponding stone texture, and then the penetrating ink-jet ink group is aligned and jet-printed on the surface of the porcelain tile blank body with the weathered stone texture after the texture identification in the step E according to the ink-jet pattern of the corresponding stone texture;
G. Firing: f, placing the ceramic tile blank with the weathered stone texture after the ink-jet decoration in a roller kiln for sintering, wherein the sintering temperature is 1150-1250 ℃, and the sintering period is 60-150 min, so as to obtain a ceramic tile sintered body with the weathered stone texture;
H. edging and polishing: performing edging and polishing treatment on the ceramic tile sintered body with the weathered stone texture obtained by sintering in the step G by using conventional edging and polishing processing equipment to obtain a semi-finished product of the ceramic tile with the weathered stone texture;
I. and (3) treating the simulated weathering effect: preparing a weathering-simulating functional reagent, wherein the weathering-simulating functional reagent comprises hydrofluoric acid, benzoic acid and hydrochloric acid; spraying the weathering simulation functional reagent on the surface of the porcelain tile semi-finished product with the weathering stone texture after edging and polishing in the step H to obtain a porcelain tile finished product with the weathering stone texture;
the digital whole body distribution system in the step B comprises an intelligent software control system and a whole body distribution device; the whole-body distributing device comprises a frame, a first transmission belt, a line forming system, a powder supplementing system and a particle forming system; the line forming system comprises a thick line forming system, a medium line forming system and a thin line forming system; the thick line forming system comprises a thick line distributing hopper positioned at the starting end of the advancing direction of the first conveying belt, a first sub-conveying belt positioned below the thick line distributing hopper, and a second sub-conveying belt positioned below the first sub-conveying belt; the medium line forming system comprises an engraving belt at the front end of the second sub-transmission belt along the advancing direction of the first transmission belt, a powder scraping hopper clung to the surface of the engraving belt, a third sub-transmission belt positioned above the powder scraping hopper and a medium line distributing hopper positioned above the third sub-transmission belt; the fine wire forming system comprises an inclined baffle plate at the front end of the third sub-conveying belt along the advancing direction of the first conveying belt and a fine wire distributing hopper above the inclined baffle plate; the powder supplementing system comprises a scraping hopper, a fourth conveying belt and a powder supplementing hopper, wherein the scraping hopper is used for inclining the front end of the baffle plate along the advancing direction of the first conveying belt, the fourth conveying belt is arranged above the scraping hopper, and the powder supplementing hopper is arranged above the fourth conveying belt; the particle forming system comprises a screen mesh at the front end of a fourth-minute transmission belt along the advancing direction of the first transmission belt, a scraping belt closely attached to the screen mesh, and a fifth-minute transmission belt above the scraping belt along the advancing direction of the first transmission belt, wherein a jacking device and a particle powder material distributing hopper are sequentially distributed on the fifth-minute transmission belt; the width of the thick line forming system and the medium line forming system in the direction perpendicular to the first conveying belt is smaller than that of the first conveying belt;
The working process of the digital whole body distribution system in the step B is as follows: firstly, inputting a digital fossil texture pattern through an intelligent software control system, driving a whole body distributing device to distribute according to the digital fossil texture pattern, then sequentially blanking a coarse line distributing hopper in the whole body distributing device, forming a powder layer on a first sub-conveying belt, dropping the powder layer onto a second sub-conveying belt along with the transmission of the first sub-conveying belt, then swinging the second sub-conveying belt along a direction perpendicular to the advancing direction of the first conveying belt to discharge powder onto the first conveying belt, forming arc-shaped coarse lines on the first conveying belt due to the fact that the first conveying belt always moves along the advancing direction, and when the first conveying belt carrying the coarse line powder moves to the lower part of a medium line forming system, the middle line material distribution hopper starts to discharge, a powder material layer is formed on a third sub-conveying belt in a lamination discharging mode, the powder material layer falls into a powder scraping hopper along with the movement of the third sub-conveying belt, powder material at the concave position of the carving belt is conveyed to a gap position of thick line powder material on a first conveying belt by the carving belt through the interaction of the powder scraping hopper and the carving belt, the powder scraping hopper and the carving belt do swinging movement along the direction perpendicular to the advancing direction of the first conveying belt in the discharging process, irregular arc-shaped distribution is formed on the first conveying belt, the carving belt is designed into concave stripes with a certain width, so that the width of arc-shaped powder material formed by the powder material at the concave position on the first conveying belt is smaller than that of arc-shaped powder material formed by a thick line material distribution system, when the first conveying belt carrying the coarse line powder layer and the medium line powder layer moves to the lower part of the fine line forming system, the fine line material distributing hopper starts to intermittently feed, powder falls onto the inclined baffle plate and then slides to the gap between the coarse line powder layer and the medium line powder layer on the first conveying belt, after that, when the first conveying belt carrying the coarse line powder layer, the medium line powder layer and the fine line powder layer moves to the lower part of the powder supplementing system, the powder supplementing hopper starts to feed, sequentially falls onto the fourth conveying belt to form laminated powder layers, then falls onto the scraping hopper, the powder supplementing powder is applied to the gaps among the coarse line powder layer, the medium line powder layer and the fine line powder layer on the first conveying belt through the scraping hopper, the powder layers after the powder supplementing operation are conveyed to the lower part of the particle forming system by the first conveying belt, the particle powder distributing hopper starts to discharge and fall onto a fifth conveying belt, then the fifth conveying belt conveys powder to a jacking device, the jacking device starts to work and pre-presses the powder to form powder blocks with a certain degree of compactness, the powder blocks move along with the fifth conveying belt and fall onto a screen with a scraping sheet, then the scraping sheet moves back and forth along the direction perpendicular to the moving direction of the first conveying belt, the powder blocks are extruded through the screen, particles with the same size as the aperture of the screen are extruded through the screen, the particles fall onto a powder layer on the first conveying belt, the powder layer is completed by powder supplement, the screen and the first conveying belt have a certain height difference due to the certain weight of the particles, the powder layer with the powder supplement is embedded under the action of gravity to form a final blank powder layer with a certain texture, then, feeding the blank powder material layer with certain textures into a die cavity of a press through a first conveying belt for back pressure molding;
F, the color of the permeation ink-jet ink set is not fixed, and different colors can be displayed in green body powder materials of different systems; for the first, second and fourth material powders, the penetrating ink 1 appears iron red, the penetrating ink 2 appears yellow, the penetrating ink 3 appears sea bluish, the penetrating ink 4 appears black, the penetrating ink 5 appears light yellow, the penetrating ink 6 appears yellow-green, and the penetrating ink 7 appears pink; for the third material powder, the penetrating ink 1 is yellow, the penetrating ink 2 is yellow gray, the penetrating ink 3 is marine blue, the penetrating ink 4 is blue, the penetrating ink 5 is rose red, the penetrating ink 6 is green, and the penetrating ink 7 is pink; for the first material powder, the second material powder and the fourth material powder, although the color development hues of 7 kinds of penetrating inks in the 3 material powders are consistent, the saturation of the color development is different, and for penetrating ink 1, penetrating ink 2, penetrating ink 3, penetrating ink 4, penetrating ink 5 and penetrating ink 6, the order of the color development saturation from high to low is: the fourth material powder is larger than the first material powder and larger than the second material powder; for the penetrating ink 7, the color saturation is ordered from high to low: the second material powder is larger than the fourth material powder and larger than the first material powder;
The weight ratio of hydrofluoric acid to benzoic acid to hydrochloric acid in the weathering-simulating functional reagent in the step I is 1-5:5-20:75-94.
2. A method of producing a porcelain tile having a weathered stone texture as set forth in claim 1, wherein: in the step A, the first material powder, the second material powder and the fourth material powder all contain 1-8% of amorphous silicon dioxide.
3. A method of producing a porcelain tile having a weathered stone texture as set forth in claim 1, wherein: and (C) in the step A, the third material powder contains 0.5-2% of tin dioxide.
4. A method of producing a porcelain tile having a weathered stone texture as set forth in claim 1, wherein: the second sub-conveying belt, the powder scraping hopper and the engraving belt in the whole-body material distribution device do swinging motion along the advancing direction perpendicular to the first conveying belt, the swinging frequency of the second sub-conveying belt is lower than that of the powder scraping hopper and the engraving belt, and the swinging pace of the second sub-conveying belt is inconsistent with that of the powder scraping hopper and the engraving belt.
5. A method of producing a porcelain tile having a weathered stone texture as set forth in claim 1, wherein: the particle forming system in the whole-body distributing device moves intermittently.
6. A method of producing a porcelain tile having a weathered stone texture as set forth in claim 1, wherein: the viscosity of the permeation ink-jet ink set in the step F is 25 to 35 mPas, the test flow rate of a 50mL flow rate cup is 11 to 15 seconds, and the specific gravity is 0.88 to 0.92g/cm 3 The surface tension is 23-29 mN/m.
7. A weathered stone textured tile product produced by the method of producing a weathered stone textured tile according to any one of claims 1 to 6.
CN202111602105.0A 2021-12-24 2021-12-24 Porcelain tile with weathered stone texture and production method thereof Active CN114276127B (en)

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