CN114619548A

CN114619548A - Rock plate with natural texture effect and manufacturing method thereof

Info

Publication number: CN114619548A
Application number: CN202210232673.4A
Authority: CN
Inventors: 李刚; 钟树铭; 李华云; 刘云飞; 夏昌奎; 余剑峰; 甄燕萍; 刘金军
Original assignee: Hangzhou Nabel Ceramic Co ltd; Jiujiang Nabel Ceramic Co ltd; Deqing Nabel Ceramic Co ltd
Current assignee: Hangzhou Nabel Ceramic Co ltd; Jiujiang Nabel Ceramic Co ltd; Deqing Nabel Ceramic Co ltd
Priority date: 2022-03-09
Filing date: 2022-03-09
Publication date: 2022-06-14
Anticipated expiration: 2042-03-09
Also published as: CN114619548B

Abstract

The invention discloses a method for manufacturing a rock plate with a natural texture effect, which comprises the following steps: A. preparing blank powder by a conventional method; B. preparing slurry for a basic digital slurry distribution system; C. molding; D. drying the blank; E. digital pulp distribution; F. drying again; G. decorating patterns; H. firing; I. and (5) edging to obtain the rock plate with the natural texture effect. The invention can carry out positioning application of the water-based ceramic slurry according to the preset pattern texture, the formed natural texture decorative effect has obvious concave-convex three-dimensional texture, and the combination of the arrangement of the spray head arrays can break through the limitation that slurry with different compositions and/or colors can only realize linear flow texture in the traditional slurry application, the lines of the slurry can also realize random arrangement, and the matching of a plurality of spray head arrays ensures that the texture of the natural stone imitation formed by the slurry application is clearer, more vivid, three-dimensional and fine, the pattern and line effects are richer, and the gradual transition effect is good.

Description

Rock plate with natural texture effect and manufacturing method thereof

Technical Field

The invention relates to a rock plate and a manufacturing method thereof, in particular to a rock plate with a natural texture effect and a manufacturing method thereof.

Background

With the continuous development of social economy, the requirements of people on living quality and living environment are continuously improved, so that the natural stone-imitating, simple and natural decorative material is deeply favored by people.

At present, various process means and materials are utilized in the market to simulate the texture of the natural stone, and the method mainly starts from two aspects: on one hand, starting from the pattern formed by printing decoration, the pattern is formed on the glaze layer on the surface of the blank body by ink-jet printing, roller printing, silk-screen printing and other modes, and then a layer of transparent protective glaze is covered on the pattern. However, the decorative effect obtained by the ink-jet printing method is easy to be similar and easily simulated, and the ink for ink-jet printing and the printing oil for roller printing and screen printing are oily and cannot be used in too large amount, otherwise, the oily pattern is separated from the water-based protective glaze to generate glaze shrinkage, thereby generating defects. On the other hand, the fabric is started from the fabric on the upper layer of the blank body, the fabric can be divided into dry fabric and wet fabric, the dry fabric is generally obtained by stamping the dry fabric, molding the dry fabric by a press, then sintering the dry fabric and polishing the dry fabric, but the surface pattern of the prepared product is rigid and monotonous, the three-dimensional layering sense is not strong and unnatural, and adopt the wet process to carry out the cloth, spray the ceramic slurry on the rock plate body through the cloth pipeline respectively, form imitative natural stone material pattern texture, often can receive the influence of ceramic slurry's colouring material mixing effect, carry out the homogeneous mixing with the thick liquids of different colours usually, the level effect of colour thick liquids is not obvious, it is relatively poor to fuse the mixing degree between the colouring material, it is difficult to control thick liquids and distribute the trend on rock plate body surface, the texture effect that leads to forming imitative natural stone material is clear lifelike enough, three-dimensional fine and smooth, pattern and lines effect are single, the poor problem of transitivity.

CN201310368652.6 discloses a ceramic tile decoration device and a decoration method, wherein the ceramic tile decoration device adopts a glaze mixer to mix decoration slurry with different colors and then spray the mixed slurry on the surface of a green brick through a glaze spraying bell jar, the decoration slurry with different colors and mixing degrees can be adjusted by changing the flow rate of the different decoration slurry, and rich textures can be formed by matching with the speed change of a conveyor belt. Although the method has low cost and convenient modification, the formed patterns are not rich enough, and the flow lines are taken as the main points, so that the control is relatively difficult.

Disclosure of Invention

The invention provides a method for manufacturing a rock plate with a natural texture effect, which aims to solve the technical problems that the pattern of the existing rock plate product is not natural and rich enough, the texture is not clear and vivid enough, and the pattern control of a glaze pouring process in production is difficult.

It is another object of the invention to provide a rock panel with a natural grain effect manufactured by the method.

In order to realize the first invention purpose, the technical scheme adopted by the invention is as follows: a method of making a rock panel having a natural grain effect, comprising the steps of:

A. preparing blank powder by a conventional method for later use;

B. preparing the slurry for the basic digital slurry distribution system: weighing mineral raw materials according to the chemical composition of the designed slurry for the basic digital slurry distribution system, adding a dispergator, a suspending agent and water in a certain proportion, and performing ball milling to prepare the slurry for the basic digital slurry distribution system;

C. molding: b, pressing and molding the blank powder prepared in the step A to form a rock plate blank with a natural texture effect;

D. drying the blank: c, drying the rock plate blank with the natural texture effect formed in the step C according to a conventional method;

E. digital pulp distribution: b, applying the slurry for the basic digital slurry distribution system prepared in the step B on the surface of the rock slab blank with the natural texture effect after drying in the step D according to the preset texture by adopting a basic digital slurry distribution system;

F. and (3) drying again: e, drying the rock plate blank with the natural texture effect after the digital slurry distribution in the step E again according to a conventional method;

G. pattern decoration: printing the pattern texture on the surface of the rock plate blank body with the natural texture effect after drying again in the step F according to the requirement of the preset pattern texture;

H. and (3) firing: firing the rock plate blank decorated by the pattern in the step G in a roller kiln at the firing temperature of 1150-1250 ℃ for 60-150 min to obtain a rock plate semi-finished product with the natural texture effect;

I. edging: carrying out edge grinding treatment on the semi-finished product of the rock plate with the natural texture effect obtained by sintering in the step H by using conventional edge grinding processing equipment to obtain a rock plate finished product with the natural texture effect;

the slurry for the basic digital slurry distribution system has 3 or more than 3 chemical compositions.

In the above steps, the conventional control means in the prior art is adopted, unless otherwise specified.

To accomplish the second object of the present invention, a rock panel having a natural grain effect manufactured according to the above-described steps is used.

And further, adding a pigment into the slurry for the basic digital cloth pulp system in the step B to prepare the slurry for the colored basic digital cloth pulp system.

Further, the slurry for the basic digital slurry distribution system in the step B has 3 chemical compositions: the first chemical composition of the slurry for the basic digital slurry distribution system is as follows by weight percent: SiO 2₂ 45%~50%，Al₂O₃ 12%~16%，CaO 11%~15%，MgO 5%~8%，K₂O 1.5%~3%，Na₂O 1.5%~3%，BaO 3%~7%，ZnO 1%~3%，B₂O₃ 0.5%~3%，Fe₂O₃≤0.5%，TiO₂The base type digital slurry distribution system slurry comprises the following components in percentage by weight, wherein the base type digital slurry distribution system slurry comprises a first chemical composition, a second chemical composition and a first chemical composition, the firing temperature of the base type digital slurry distribution system slurry is lower, and the base type digital slurry distribution system slurry is used for forming a transparent bright surface glaze effect: SiO 2₂ 43%~49%，Al₂O₃ 20%~25%，CaO 5%~10%，MgO 1.5%~4%，K₂O 0.5%~2%，Na₂O 1.5%~3%，BaO 4%~8%，ZnO 1.5%~4%，B₂O₃ 0.5%~3%，Fe₂O₃≤0.5%，TiO₂The sintering temperature of the slurry for the basic type digital slurry distribution system with the second chemical composition is higher than that of the slurry for the first basic type digital slurry distribution system, and the slurry is used for forming a semitransparent matte glaze effect, wherein the third chemical composition of the slurry for the basic type digital slurry distribution system is calculated by weight percent: SiO 2₂ 62%~68%，Al₂O₃ 20%~23%，CaO 0.1%~0.7%，MgO 0.05%~0.2%，K₂O 3.5%~5%，Na₂O 2.5%~3.5%，ZrO₂ 1%~3%，Fe₂O₃≤0.5%，TiO₂The burning loss is less than or equal to 0.5 percent, the burning loss is less than or equal to 8 percent, the burning temperature of the slurry for the basic digital slurry distribution system with the third chemical composition is higher, and the slurry is used for forming the effect of opaque matt porcelain surface.

Further, the specific gravity of the slurry for the basic digital slurry distribution system in the step B is 1.20-1.85 g/cm³The flow rate of the 50mL flow cup is 10-25 s, the viscosity is 40-500 mPa.s, the surface tension is 50-70 mN/m, the Reynolds number is 5-50, the Weber number is 70-130, and the Bunde number is 0.12-0.25.

Specific gravity, flow rate, viscosity and surface tension are among the conventional physical property parameters, while the reynolds number, weber number and bond number are among dimensionless numbers. Where Reynolds number is a dimensionless number that can be used to characterize fluid flow, denoted Re, and is a measure of the ratio of inertial force to viscous force of a fluid, it can be expressed as follows: re = dv ρ/μ. In the invention, d is the diameter of slurry outlet, namely the diameter of slurry flowing through a pipeline, v is the slurry injection speed, ρ is the specific gravity of the slurry, and μ is the viscosity of the slurry, when the Reynolds number is small, the influence of viscous force on a flow field is greater than the inertia force, the disturbance of the flow velocity in the flow field is attenuated due to the viscous force, the fluid flow is stable and is laminar flow; on the contrary, if the reynolds number is larger, the influence of the inertia force on the flow field is larger than the viscous force, the fluid flow is unstable, the small change of the flow velocity is easy to develop and strengthen, and the turbulent and irregular turbulence is formed.

The Weber number, which represents the ratio of inertial force to surface tension effect, is denoted by We and can be represented by the following equation: we = ρ v²d/gamma. In the invention, rho is the specific gravity of the slurry, v is the spraying speed of the slurry, d is the slurry outlet diameter, namely the diameter of the slurry flowing through a pipeline, gamma is the surface tension of the slurry, and the smaller the Weber number, the more important the surface tension is, such as the problems of small scale as capillary phenomenon, soap bubbles, surface tension waves and the like. In general, the large scale problem, with a Weber number much greater than 1.0, the effect of surface tension is negligible.

The bond number is a dimensionless number determined due to the influence of surface tension, denoted by Bo, and can be represented by the following sub-formula: bo = ρ gd²And/gamma. In the invention, rho is the specific gravity of the slurry, g is the gravity acceleration, d is the slurry outlet diameter, namely the diameter of the slurry flowing through the pipeline, gamma is the surface tension of the slurry, the bond number represents the ratio of the gravity to the surface tension, when the action of the gravity is smaller than the surface tension, the surface tension plays a dominant role, and the liquid is spherical.

It should be noted that the slurry injection speed v involved in the calculation of three dimensionless numbers, i.e., the reynolds number, the weber number and the bond number, is not 10 to 25s of the flow speed of the 50mL flow speed cup of the slurry for the basic digital slurry distribution system, and 10 to 25s of the flow speed of the 50mL flow speed cup of the slurry for the basic digital slurry distribution system is the time required for the slurry for the 50mL basic digital slurry distribution system to completely flow in the 50mL flow speed cup under the action of gravity.

The traditional ink jet device adopts organic solvent type ceramic ink or organic solvent type digital glaze, and is characterized in that the granularity of the ceramic ink or the digital glaze needs to be controlled to the fineness that d99 is not more than 0.85 mu m (the granularity of 99% of particles in the cumulative distribution of the granularity is not more than 0.85 mu m), and in order to ensure that the organic solvent type ceramic ink or the organic solvent type digital glaze has good spray printing performance, more liquid dispersing agents, liquid stabilizing agents, liquid suspending agents, solvents and the like need to be introduced, so that the solid content of the organic solvent type ceramic ink or the organic solvent type digital glaze is not more than 50%, and thus, the dimensionless numerical control of the Reynolds number, the Weber number, the Bangdard number and the like of the organic solvent type ceramic ink or the organic solvent type digital glaze is easier to control. The slurry for the basic digital slurry distribution system is water-based ceramic slurry, the fineness of the slurry is controlled to be about 45 mu m in d99 (the particle size of 99 percent of particles in the cumulative distribution of the particle size is not more than 45 mu m), most of the particle size of the slurry is more than 1 mu m, and the solid content of the slurry is not lower than 60 percent, so that compared with organic solvent type ceramic ink or organic solvent type digital glaze, the water-based ceramic slurry has thicker particle size, easier sedimentation of the slurry, difficult control of properties such as suspension property and moisture retention property, and larger control difficulty of dimensionless numbers such as Reynolds number, Weber number and Bunde number related to rheological parameters such as viscosity, surface tension, specific gravity and the like.

According to the knowledge of fluid mechanics, the Reynolds number Re < 2300 is laminar state, Re < 2300 < 4000 is transitional state, and Re > 4000 is turbulent state. Obviously, the slurry for the basic digital slurry distribution system is in a laminar flow state and is limited between 5 and 50, on one hand, the slurry for the basic digital slurry distribution system is water-based ceramic slurry formed by mixing and grinding minerals such as natural clay, feldspar, quartz and the like with water, basic rheological performance parameters such as specific gravity, viscosity, flow velocity and the like are in a range, and the caliber of emergent slurry provided by a flow limiting mechanism in the basic digital slurry distribution system is smaller, namely the diameter d of the emergent slurry is smaller, so that the Reynolds number of the slurry for the basic digital slurry distribution system is in the laminar flow state; on the other hand, although increasing the reynolds number of the slurry for the basic digital slurry distribution system is beneficial to the flow transmission of the slurry for the basic digital slurry distribution system in the slurry distribution device, once increasing the reynolds number will significantly affect the printing effect of the slurry on the surface of the blank, as mentioned in the first point, the slurry for the basic digital slurry distribution system is a water-based ceramic slurry formed by mixing and grinding minerals such as natural clay, feldspar, quartz, etc. with water, therefore, the reynolds number also has an upper limit, if increasing the reynolds number once, the solid content of the slurry needs to be significantly reduced, that is, the water content of the slurry is increased, and the pattern texture effect on the surface of the blank needs to be realized by the solid components in the slurry, if excessively increasing the reynolds number, the water content of the slurry is too large, so that the solid components attached to the surface of the blank are greatly reduced, and it is difficult to realize the concavo-convex three-dimensional texture, the green body absorbs the water in the slurry to adhere solid components to the green body, and if the green body absorbs too much water, the green body is easy to have too low strength, so that the defects of edge breakage, corner breakage, even cracking and the like caused by insufficient strength are caused.

The Weber number represents the ratio of the inertia force to the surface tension effect, the slurry for the basic digital slurry distribution system needs to flow and transmit smoothly in the slurry distribution device, and a certain inertia force is needed to prevent the slurry from blocking in a pipeline.

The Bunde number represents the ratio of gravity to surface tension, the concave-convex three-dimensional texture on the surface of the blank is formed by arranging a plurality of small droplets on the surface of the blank according to the requirement of a preset texture, for each small droplet, if the gravity action is greater than the surface tension action, the small droplets are easy to be completely spread on the surface of the blank, the realization of fine texture is not facilitated, similar to pixels on a liquid crystal display screen, the more the pixels are, the clearer the image is, the less the pixels are, one block is formed, the more the image is blurred, if each small droplet is completely spread, the larger the overlapping is inevitable, macroscopically, the pattern formed by digital pulp distribution is blurred, and if the gravity action is less than the surface tension action, the small droplets are approximately spherical and can be combined with the blank at a certain wetting angle on the surface of the blank, so that more positions can be left for the small droplets sprayed on the back, similar to the liquid crystal display screen, the number of pixels is more, the image is clearer, and the pattern formed by the digital cloth pulp is clearer and more stereoscopic when viewed macroscopically, so that the texture layer of the concave-convex stereoscopic structure is more favorably formed. The bond number of the slurry for the basic digital slurry distribution system is 0.12-0.25, and clear and three-dimensional pattern texture layers can be presented.

And furthermore, a step of applying bottom slurry is added between the step D and the step E, wherein the bottom slurry is prepared by weighing mineral raw materials according to the designed chemical composition of the bottom slurry, and adding a dispergator, a suspending agent and water in a certain proportion for ball milling. The bottom slurry is applied by adopting one of a spray disc and a glaze spraying cabinet.

Furthermore, the basic digital pulp distribution system of the step E comprises a computer control system and a pulp distribution device; the slurry distribution device comprises a spray head array formed by combining a plurality of spray heads; the sprayer comprises a filtering device, a digital flowmeter, a slurry distribution signal input end, a sprayer cavity, an extrusion device, a cache cavity and a current limiting mechanism; the lower end of the extrusion device is made of a transparent material, and the infrared signal generator is coated in the transparent material; the upper end of the extrusion device is of a cylindrical solid structure, the lower end of the extrusion device is of a truncated cone-shaped convex solid structure, and the diameter of the truncated cone is smaller the closer to the lower end; the inner wall of the cache cavity is covered with a layer of hydrophobic film; the upper end of the cache cavity is of a cylindrical cavity structure, the inner wall of the lower end of the cache cavity is matched with the lower end of the truncated cone-shaped convex solid structure of the extrusion device and is of a concave truncated cone structure, and the diameter of the truncated cone-shaped cavity is smaller as the cache cavity is closer to the lower end; the flow limiting mechanism comprises a telescopic baffle and a flushing device; the upper end of the telescopic baffle is made of transparent silica gel, and the transparent silica gel is coated with an infrared signal receiver for receiving an infrared signal sent by an infrared signal generator in the lower end of the extrusion device; and a plurality of water outlet holes are distributed at the upper end of the flushing device.

Furthermore, the computer control system is used for controlling the pulp distribution device to distribute pulp according to the preset texture.

Furthermore, the spray head array is a single-mode spray head array formed by single rows of spray heads distributed in parallel at equal intervals, and can be suitable for pattern texture printing which is not particularly complex.

Furthermore, the nozzle array is an embedded mode nozzle array formed by double rows of nozzles distributed equidistantly and in parallel, and is suitable for pattern texture printing with strong layering sense and fine texture.

Furthermore, the nozzle array is an interactive mode nozzle array with nozzles distributed in a crossed manner, and is suitable for pattern texture printing with rich colors, natural transition of colors and textures and gradual change.

Furthermore, the filtering device is a screen mesh, and the mesh number of the screen mesh is 50-600 meshes.

Furthermore, the filtering device is a screen mesh, and the mesh number of the screen mesh is 200-325 meshes.

Compared with the fineness requirement of the traditional ink-jet decoration on the small-particle-size ink with the particle size not larger than 0.85 mu m, the cloth system in the production of the digital gunite decorative rock plate can expand 0.85 mu m to 45 mu m, namely the basic digital cloth system can be suitable for the large-particle-size slurry with the particle size of 45 mu m. The traditional ink-jet device is generally used for spraying and distributing oily ink, the ink needs to be ground to 0.85 μm, if the traditional ink-jet device is used for spraying and distributing water-based slurry, the water-based slurry needs to be ground to 0.85 μm, and if the basic digital slurry distribution system is adopted, the slurry needs to be ground to about 45 μm, so that the power consumption generated by grinding can be obviously reduced, and the power consumption of each ton of slurry can be reduced from 2000-4000 degrees to 200 degrees preliminarily estimated.

In addition, if the slurry is ground too finely, other slurry rheology problems can arise. For example, the thixotropy is obviously deteriorated, which may be caused by that the temperature of the slurry is rapidly increased although the granularity of the slurry is gradually reduced along with the extension of the grinding time, so that the dispergator is partially failed, and the negative effect on the dispergator failure is more and more strong along with the extension of the grinding time, so that the thixotropy of the slurry is finally deteriorated; in addition, the grinding time is greatly increased, so that the temperature of the slurry is higher, a layer of solid layer is formed on the surface of the slurry due to the rapid evaporation of surface moisture in the standing process of the ground slurry, namely the common 'skinning' defect in the production process, the formed skinning is difficult to be completely broken through the stirring effect in the subsequent use process, solid aggregates are formed, the slurry is not uniform, and the presenting effect of the digital cloth slurry on the surface of the blank body is influenced.

Further, the filter device is honeycomb ceramic.

Furthermore, the digital flowmeter can display the flow rate of the slurry flowing into the spray head in real time and feed the flow rate back to the computer control system, and then the computer control system adjusts the flow rate of the slurry. The slurry flow rate referred to herein is the weight/volume of slurry passing through the meter per unit time. If the flow rate of the slurry is monitored to be too small, the digital flow meter can be adjusted through the computer control system, so that the flow rate of the slurry is properly increased, because the flow rate of the slurry is too small, stable slurry supply to the spray head is influenced, the printing effect is unstable, if the digital flow meter is adjusted, the slurry is possibly viscous or the slurry supply channel is blocked, if the filter device is blocked, because large-particle agglomerates or impurities in the slurry block the meshes of the filter device, the filter device needs to be replaced or cleaned. If the flow velocity of the pulp is monitored to be overlarge, the digital flow meter can be adjusted through the computer control system, so that the flow velocity of the pulp is properly reduced, and the flow velocity of the pulp is overlarge, so that the flow limiting mechanism is easily impacted by the larger pulp, the arc of the pulp ejected from the flow limiting mechanism is unstable, and the printing effect is influenced.

Further, the extrusion device is made of transparent silica gel.

Furthermore, the hydrophobic membrane is mixed with high-hardness substances such as carborundum, so that the friction loss condition between the extrusion device and the inner wall of the cache cavity can be effectively improved, and the service life of the cache cavity is prolonged.

Further, the retractable baffle is in one of a cuboid structure and a semicircular structure.

Further, the flushing device is one of a cuboid structure and a semicircular structure.

Furthermore, the telescopic baffle and the flushing device are both of cuboid structures, and a flow limiting mechanism formed by the telescopic baffle and the flushing device is of a cross structure; the telescopic baffle and the flushing device are both of semicircular structures, and the flow limiting mechanism formed by the telescopic baffle and the flushing device is of a petal-shaped structure.

Furthermore, the opening and closing gap of the telescopic baffle is continuously controlled by 0-100%.

Further, the working process of the pulp distribution system is as follows: when the transmission belt bears the rock plate blank and moves to the lower end of the pulp distribution device, the computer control system drives the pulp distribution device to distribute pulp on the surface of the rock plate blank according to the input preset pulp distribution draft, pulp is required to be filtered by the filtering device before entering the spray head, granular aggregates in the pulp are removed, so as to prevent the nozzle from being blocked, then flows through the digital flowmeter, and then enters the nozzle cavity, when the liquid level of the slurry in the nozzle cavity is higher than the inlet of the cache cavity, namely flows into the buffer cavity, then the pulp distribution signal input end receives a digital signal from a computer control system to drive the extrusion device to work, the extrusion device begins to descend and enters the buffer cavity, the slurry is extruded out of the flow limiting mechanism, the telescopic baffle plate of the flow limiting mechanism is also controlled by the computer control system, controlling the thickness and the shape of lines printed on the surface of the rock plate blank by the slurry through adjusting the opening and closing gaps; when the infrared signal generator at the lower end of the extrusion device and the infrared signal receiver at the upper end of the telescopic baffle plate monitor that the spray head is blocked, the spray head stops working and enters a cleaning state, at the moment, the telescopic baffle plate is completely stretched, the washing device is closed, water outlet holes at the upper end of the washing device are used for washing, and until the infrared signal generator at the lower end of the extrusion device and the infrared signal receiver at the upper end of the telescopic baffle plate monitor the dredging state, the washing device is completely stretched, the telescopic baffle plate is closed again, and the spray head enters the working state again.

Further, a step of applying a protective glaze is added between the step E and the step F.

Further, the pattern decoration in the step G adopts a common ink jet printing mode, and an ink jet printer prints pattern textures on the surface of the rock plate blank which is dried again in the step F and has a natural texture effect.

Further, the pattern decoration in the step G adopts a penetrating ink jet printing mode, and an ink jet printing machine prints pattern textures on the surface of the rock plate blank dried again in the step F and having the natural texture effect.

And G, adding texture recognition between the step F and the step G, wherein the texture recognition is to recognize the digital pulp distribution texture on the surface of the rock blank body with the natural texture effect after being dried again in the step F by adopting an ultra-high-definition digital camera and send a network signal to an ink-jet printer, then the ink-jet printer calls the pattern texture corresponding to the digital pulp distribution texture, and the surface of the rock blank body with the natural texture effect after being dried again in the step F is subjected to positioning ink-jet printing pattern decoration.

Further, the pattern decoration in the step G adopts a screen printing mode, and a screen printing machine prints pattern textures on the surface of the rock plate blank which is dried again in the step F and has a natural texture effect.

And further, the pattern decoration in the step G adopts a rubber roller printing mode, and a rubber roller printer is used for printing pattern textures on the surface of the rock plate blank which is dried again in the step F and has a natural texture effect.

Further, after the step I, a polishing process is adopted for treatment.

The beneficial effects of the invention are as follows: on one hand, the traditional disc-spraying type slurry distribution covers the whole surface of a blank body in a superposed mode, and the decoration of the surface of the blank body is only limited to pure-color slurry added with pigment, but the basic digital slurry distribution system in the rock plate manufacturing with the natural texture effect inputs digital patterns through a computer control system and drives a slurry distribution device to carry out slurry distribution decoration, and can carry out positioning distribution according to the required pattern textures; on the other hand, compared with the slurry distribution in a disc type, the traditional slurry distribution texture formed by spraying a plurality of slurry distribution pipelines is improved to a certain extent, a plurality of slurries with compositions and/or colors can be simultaneously distributed on the surface of a blank, but only the textures of different slurries with compositions and/or colors can be presented in an interval adjacent mode, namely only linear type flow textures can be presented, the decoration effect is single, the layering effect of the color slurries is not obvious, the blending degree of pigments is poor, the distribution trend of the slurries on the surface of the rock blank is difficult to control, the texture effect of the formed natural stone imitation is not clear, vivid, three-dimensional and fine, the pattern and line effect is single, and the transitional property is poor, but the basic digital slurry distribution system in the rock manufacture with the natural texture effect inputs digital patterns through a computer control system and drives a slurry distribution device to carry out slurry distribution decoration, the method can perform positioning and cloth application according to preset pattern textures, and can perfectly realize the organic combination printing effect of points, lines and surfaces on the same plane by controlling the amount of slurry entering a cache cavity, adjusting the thickness of slurry discharged by a flow limiting mechanism and controlling the thickness of slurry discharged by the flow limiting mechanism, and is different from the traditional plane superposition type slurry distribution effect The gradual transition effect is good.

Drawings

FIG. 1 is a schematic view of a slurry distribution apparatus distributing slurry to a rock plate blank;

wherein, the device comprises 1-a frame, 2-a transmission belt, 3-a rock plate blank, 4-a slurry distribution device and 4-1-a spray head.

FIG. 2 is a schematic top view of a slurry distribution device for distributing slurry to a rock plate blank;

wherein, fig. 2a is a schematic plan view of a rock plate blank slurry distribution device employing a single mode nozzle array to distribute slurry to the rock plate blank in a direction perpendicular to the advancing direction of the conveyor belt; FIG. 2b is a schematic top view of a slurry distribution device employing an array of spray heads in a mosaic pattern for distributing slurry to a rock plate blank perpendicular to the direction of travel of the conveyor belt; FIG. 2c is a schematic top view of a slurry distribution apparatus employing an alternating pattern nozzle array for distributing slurry to a rock plate blank, perpendicular to the direction of travel of the conveyor belt; the arrow direction is the advancing direction of the conveying belt; 2-transmission belt, 3-rock plate blank, 4-slurry distribution device, 4-1-spray head.

FIG. 3 is a schematic view of a spray head structure in the slurry distribution device;

the device comprises a filter device 5, a digital flowmeter 6, a nozzle cavity 7, a slurry distribution signal input end 8, an extrusion device 9, an infrared signal transmitter 10, a buffer cavity 11, a hydrophobic membrane 12, a telescopic baffle 13, an infrared signal receiver 14, and slurry enters the nozzle in the direction of an arrow.

FIG. 4 is a schematic view of the extrusion device and the buffer chamber in a guniting operation;

wherein, 9-extrusion device, 11-buffer cavity, 13-current-limiting mechanism.

FIG. 5 is a schematic view of the cross configuration of the flow restriction mechanism; wherein, 14-infrared signal receiver, 15-retractable baffle, 16-flushing device.

FIG. 6 is a schematic view of a cross-shaped configuration of the flow restriction mechanism in a purge state; wherein, 14-infrared signal receiver, 15-retractable baffle, 16-flushing device.

FIG. 7 is a schematic view of the operating condition of the flow restriction mechanism in a petal configuration; wherein, 14-infrared signal receiver, 15-retractable baffle, 16-flushing device.

FIG. 8 is a schematic view of the flow restriction mechanism in a petal configuration in a purge state; wherein, 14-infrared signal receiver, 15-retractable baffle, 16-flushing device.

Detailed Description

Example 1

As shown in fig. 1-8, the present invention is implemented by the following steps:

A. preparing blank powder by a conventional method for later use;

B. preparing the slurry for the basic digital slurry distribution system: weighing mineral raw materials according to the chemical composition of the designed basic type digital slurry distribution system slurry, adding a dispergator, a suspending agent and water in a certain proportion for ball milling, and preparing the three chemically-composed basic type digital slurry distribution system slurries: the first chemical composition of the slurry for the basic digital slurry distribution system is as follows by weight percent: SiO 2₂ 45%，Al₂O₃ 16%，CaO 11%，MgO 8%，K₂O 1.5%，Na₂O 3%，BaO 3%，ZnO 3%，B₂O₃ 0.5%，Fe₂O₃≤0.5%，TiO₂The base type digital slurry distribution system slurry has the following chemical compositions in percentage by weight: SiO 2₂ 49%，Al₂O₃ 20%，CaO 10%，MgO 1.5%，K₂O 2%，Na₂O 1.5%，BaO 8%，ZnO 1.5%，B₂O₃3%，Fe₂O₃≤0.5%，TiO₂The sintering temperature of the slurry for the basic digital slurry distribution system is higher than that of the slurry for the first basic digital slurry distribution system, and the slurry can be used for forming a semitransparent matte glaze effect, and the third chemical composition of the slurry for the basic digital slurry distribution system is as follows by weight percent: SiO 2₂ 62%，Al₂O₃ 23%，CaO 0.1%，MgO 0.2%，K₂O 3.5%，Na₂O 3.5%，ZrO₂ 1%，Fe₂O₃≤0.5%，TiO₂The burning loss is less than or equal to 0.5 percent and less than or equal to 8 percent, the burning temperature of the slurry for the basic digital slurry distribution system is higher, and the slurry can be used for forming an opaque matt porcelain surface effect; the rheological property parameters of the slurry for the three basic digital slurry distribution systems are adjusted to be consistent, and the specific gravity is 1.55g/cm³The flow rate of a 50mL flow cup is 20s, the viscosity is 135mPa · s, the surface tension is 70mN/m, the Reynolds number is 18.4, the Weber number is 71, and the bond number is 0.14;

the basic digital pulp distribution system comprises a computer control system and a pulp distribution device 4; the pulp distribution device 4 comprises a spray head array formed by combining a plurality of spray heads; the spray head array is an embedded mode spray head array formed by double rows of spray heads which are distributed equidistantly and in parallel; the spray head 4-1 comprises a filtering device 5, a digital flow meter 6, a slurry distribution signal input end 8, a spray head cavity 7, an extrusion device 9, a cache cavity 11 and a flow limiting mechanism 13; the lower end of the extrusion device 9 is made of a transparent material, and an infrared signal transmitter 10 is coated in the transparent material; the upper end of the extrusion device 9 is of a cylindrical solid structure, the lower end of the extrusion device is of a circular truncated cone-shaped convex solid structure, and the diameter of the circular truncated cone is smaller the closer to the lower end; the inner wall of the cache cavity 11 is covered with a layer of hydrophobic film; the upper end of the cache cavity 11 is of a cylindrical cavity structure, the inner wall of the lower end of the cache cavity is matched with the lower end of the truncated cone-shaped convex solid structure of the extrusion device 9 and is of a concave truncated cone structure, and the diameter of the truncated cone-shaped cavity is smaller as the cache cavity is closer to the lower end; the flow limiting mechanism 13 comprises a telescopic baffle 15 and a flushing device 16; the upper end of the telescopic baffle 15 is made of transparent silica gel, and the transparent silica gel is coated with an infrared signal receiver 14 for receiving an infrared signal sent by an infrared signal transmitter 10 in the lower end of the extrusion device 9; a plurality of water outlet holes are distributed at the upper end of the washing device 16; the telescopic baffle 15 and the flushing device 16 are both of cuboid structures; the filtering device 5 is a screen mesh with the mesh number of 600 meshes;

the basic digital pulp distribution system comprises the following working processes: when a transmission belt 2 on a frame 1 bears a rock plate blank 3 and moves to the lower end of a slurry distribution device 4, a computer control system drives the slurry distribution device 4 to distribute slurry on the surface of the rock plate blank 3 according to an input preset slurry distribution draft, slurry is required to be filtered by a filtering device 5 before entering a spray head 4-1 to remove granular aggregates in the slurry so as to prevent the spray head 4-1 from being blocked, then the slurry flows through a digital flow meter 6 and then enters a spray head cavity 7, when the liquid level of the slurry in the spray head cavity 7 is higher than the inlet of a cache cavity 11, the slurry flows into the cache cavity 11, then a slurry distribution signal input end 8 receives a digital signal from the computer control system to drive an extrusion device 9 to work, the extrusion device 9 starts to descend and enters the cache cavity 11, a slurry flow limiting mechanism 13 and a telescopic baffle 15 of the flow limiting mechanism 13 are also controlled by the computer control system, the thickness and shape control of the lines printed on the surface of the rock plate blank 3 by the slurry is realized through the adjustment of the opening and closing gaps; when the infrared signal transmitter 10 at the lower end of the extrusion device 9 and the infrared signal receiver 14 at the upper end of the telescopic baffle 15 monitor that the spray head 4-1 is blocked, the spray head 4-1 stops working and enters a cleaning state, at the moment, the telescopic baffle 15 is completely extended, the flushing device 16 is closed, water outlet holes at the upper end of the flushing device 16 are used for flushing water, and when the infrared signal transmitter 10 at the lower end of the extrusion device 9 and the infrared signal receiver 14 at the upper end of the telescopic baffle 15 monitor a dredging state, the flushing device 16 is completely extended, the telescopic baffle 15 is closed again, and the spray head enters a working state again;

G. pattern decoration: according to the requirement of the preset pattern texture, printing the pattern texture on the surface of the rock plate blank body with the natural texture effect after drying again in the step F by adopting a rubber roller printing mode through a rubber roller printing machine;

H. and (3) firing: firing the rock plate blank with the natural texture effect decorated by the pattern in the step G in a roller kiln at the firing temperature of 1150 ℃ for 150min to obtain a rock plate semi-finished product with the natural texture effect;

I. edging: and D, utilizing conventional edging processing equipment to carry out edging treatment on the semi-finished product of the rock plate with the natural texture effect obtained by sintering in the step H, so as to obtain a rock plate finished product with the natural texture effect.

Example 2

A. preparing blank powder by a conventional method for later use;

B. preparing bottom slurry: weighing mineral raw materials according to the designed chemical composition of the bottom slurry, adding a dispergator, a suspending agent and water in a certain proportion, and carrying out ball milling to prepare the bottom slurry;

C. preparing the slurry for the basic digital slurry distribution system: weighing mineral raw materials according to the chemical composition of the designed basic type digital slurry distribution system slurry, adding a dispergator, a suspending agent and water in a certain proportion for ball milling, and preparing the three chemically-composed basic type digital slurry distribution system slurries: the first chemical composition of the slurry for the basic digital slurry distribution system is as follows by weight percent: SiO 2₂ 47%，Al₂O₃ 14%，CaO 13%，MgO 7%，K₂O 2%，Na₂O 2%，BaO 5%，ZnO 2%，B₂O₃ 2%，Fe₂O₃≤0.5%，TiO₂The base type digital slurry distribution system slurry has the following chemical compositions in percentage by weight: SiO 2₂ 46%，Al₂O₃ 23%，CaO 7%，MgO 3%，K₂O 1%，Na₂O 2%，BaO 6%，ZnO 2%，B₂O₃ 2%，Fe₂O₃≤0.5%，TiO₂The sintering temperature of the slurry for the basic digital slurry distribution system is higher than that of the slurry for the first basic digital slurry distribution system, and the slurry can be used for forming a semitransparent matte glaze effect, and the third chemical composition of the slurry for the basic digital slurry distribution system is as follows by weight percent: SiO 2₂ 66%，Al₂O₃ 21%，CaO 0.5%，MgO 0.1%，K₂O 4%，Na₂O 3%，ZrO₂ 2%，Fe₂O₃≤0.5%，TiO₂The burning loss is less than or equal to 0.5 percent and less than or equal to 8 percent, the burning temperature of the slurry for the basic digital slurry distribution system is higher, and the slurry can be used for forming an opaque matt porcelain surface effect; three basic type digital clothThe rheological property parameters of the slurry for the slurry system are adjusted to be consistent, and the specific gravity is 1.85g/cm³The flow rate of a 50mL flow cup is 25s, the viscosity is 500mPa · s, the surface tension is 60mN/m, the Reynolds number is 5.9, the Weber number is 98.9, and the bond number is 0.19;

D. molding: b, pressing and molding the blank powder prepared in the step A to form a rock plate blank with a natural texture effect;

E. drying the blank: d, drying the rock plate blank with the natural texture effect formed in the step D according to a conventional method;

F. applying primer slurry: b, applying the bottom slurry prepared in the step B on the surface of the rock plate blank body with the natural texture effect after being dried in the step E;

G. digital pulp distribution: c, applying the slurry for the basic digital slurry distribution system prepared in the step C to the surface of the rock slab blank with the natural texture effect after the bottom slurry is applied in the step F by adopting a basic digital slurry distribution system according to a preset texture;

the basic digital pulp distribution system comprises a computer control system and a pulp distribution device 4; the slurry distribution device 4 comprises a spray head array formed by combining a plurality of spray heads; the spray head array is a single-mode spray head array formed by single rows of spray heads distributed in parallel at equal intervals; the spray head 4-1 comprises a filtering device 5, a digital flow meter 6, a slurry distribution signal input end 8, a spray head cavity 7, an extrusion device 9, a cache cavity 11 and a flow limiting mechanism 13; the lower end of the extrusion device 9 is made of a transparent material, and an infrared signal transmitter 10 is coated in the transparent material; the upper end of the extrusion device 9 is of a cylindrical solid structure, the lower end of the extrusion device is of a truncated cone-shaped convex solid structure, and the diameter of the truncated cone is smaller the closer to the lower end; the inner wall of the cache cavity 11 is covered with a layer of hydrophobic film; the upper end of the cache cavity 11 is of a cylindrical cavity structure, the inner wall of the lower end of the cache cavity is matched with the lower end of the truncated cone-shaped convex solid structure of the extrusion device 9 and is of a concave truncated cone structure, and the diameter of the truncated cone-shaped cavity is smaller as the cache cavity is closer to the lower end; the flow limiting mechanism 13 comprises a telescopic baffle 15 and a flushing device 16; the upper end of the telescopic baffle 15 is made of transparent silica gel, and the transparent silica gel is coated with an infrared signal receiver 14 for receiving an infrared signal sent by an infrared signal transmitter 10 in the lower end of the extrusion device 9; a plurality of water outlet holes are distributed at the upper end of the washing device 16; the telescopic baffle 15 and the flushing device 16 are both of semicircular structures; the filtering device 5 is a screen mesh with the mesh number of 50 meshes;

the basic digital slurry distribution system has the working process as follows: when a transmission belt 2 on a frame 1 bears a rock plate blank 3 and moves to the lower end of a slurry distribution device 4, a computer control system drives the slurry distribution device 4 to distribute slurry on the surface of the rock plate blank 3 according to an input preset slurry distribution draft, slurry is required to be filtered by a filtering device 5 before entering a spray head 4-1 to remove granular aggregates in the slurry so as to prevent the spray head 4-1 from being blocked, then the slurry flows through a digital flow meter 6 and then enters a spray head cavity 7, when the liquid level of the slurry in the spray head cavity 7 is higher than the inlet of a cache cavity 11, the slurry flows into the cache cavity 11, then a slurry distribution signal input end 8 receives a digital signal from the computer control system to drive an extrusion device 9 to work, the extrusion device 9 starts to descend and enters the cache cavity 11, a slurry flow limiting mechanism 13 and a telescopic baffle 15 of the flow limiting mechanism 13 are also controlled by the computer control system, the thickness and shape control of the lines printed on the surface of the rock plate blank 3 by the slurry is realized through the adjustment of the opening and closing gaps; when the infrared signal transmitter 10 at the lower end of the extrusion device 9 and the infrared signal receiver 14 at the upper end of the telescopic baffle 15 monitor that the spray head 4-1 is blocked, the spray head 4-1 stops working and enters a cleaning state, at the moment, the telescopic baffle 15 is completely extended, the flushing device 16 is closed, water outlet holes at the upper end of the flushing device 16 are used for flushing water, and when the infrared signal transmitter 10 at the lower end of the extrusion device 9 and the infrared signal receiver 14 at the upper end of the telescopic baffle 15 monitor a dredging state, the flushing device 16 is completely extended, the telescopic baffle 15 is closed again, and the spray head enters a working state again;

H. applying a protective glaze: c, applying protective glaze to the surface of the rock slab blank with the natural texture effect after the digital slurry distribution in the step G by adopting a glaze spraying cabinet;

I. and (3) drying again: drying the rock plate blank with the natural texture effect after the protective glaze is applied in the step H again according to a conventional method;

J. pattern decoration: b, according to the requirement of the preset pattern texture, printing the pattern texture on the surface of the rock plate blank with the natural texture effect after the re-drying in the step I by a screen printing machine in a screen printing mode;

K. and (3) firing: placing the rock plate blank decorated by the patterns in the step J into a roller kiln for firing, wherein the firing temperature is 1250 ℃, and the firing period is 60min, so as to obtain a rock plate semi-finished product with the natural texture effect;

l, edging and polishing: and D, utilizing conventional edging and polishing processing equipment to carry out edging and polishing treatment on the semi-finished product of the rock plate with the natural texture effect obtained by sintering in the step K, so as to obtain a rock plate finished product with the natural texture effect.

Example 3

A. preparing blank powder by a conventional method for later use;

C. preparing the slurry for the basic digital slurry distribution system: weighing mineral raw materials according to the chemical composition of the designed basic type digital slurry distribution system slurry, adding a dispergator, a suspending agent and water in a certain proportion for ball milling, and preparing the three chemically-composed basic type digital slurry distribution system slurries: the first chemical composition of the slurry for the basic digital slurry distribution system is as follows by weight percent: SiO 2₂ 48%，Al₂O₃ 15%，CaO 12%，MgO 6%，K₂O 2.5%，Na₂O 2.5%，BaO 6%，ZnO 1.5%，B₂O₃2.5%，Fe₂O₃≤0.5%，TiO₂The base type digital slurry distribution system slurry has the following chemical compositions in percentage by weight: SiO 2₂ 47%，Al₂O₃ 22%，CaO 8%，MgO 3.5%，K₂O 1.5%，Na₂O 2%，BaO 5%，ZnO 2.5%，B₂O₃ 0.5~3%，Fe₂O₃≤0.5%，TiO₂The sintering temperature of the slurry for the basic digital slurry distribution system is higher than that of the slurry for the first basic digital slurry distribution system, and the slurry can be used for forming a semitransparent matte glaze effect, and the third chemical composition of the slurry for the basic digital slurry distribution system is as follows by weight percent: SiO 2₂ 64%，Al₂O₃22%，CaO 0.3%，MgO 0.15%，K₂O 4.5%，Na₂O 3.2%，ZrO₂ 2.5%，Fe₂O₃≤0.5%，TiO₂The burning loss is less than or equal to 0.5 percent and less than or equal to 8 percent, the burning temperature of the slurry for the basic digital slurry distribution system is higher, and the slurry can be used for forming an opaque matt porcelain surface effect; the rheological property parameters of the slurry for the three basic digital slurry distribution systems are adjusted to be consistent, and the specific gravity is 1.20g/cm³The flow rate of a 50mL flow cup is 10s, the viscosity is 40mPa · s, the surface tension is 50mN/m, the Reynolds number is 48, the Weber number is 76.9, and the bond number is 0.15;

F. applying base slurry: b, applying the bottom slurry prepared in the step B on the surface of the rock plate blank body with the natural texture effect after being dried in the step E;

the basic digital pulp distribution system comprises a computer control system and a pulp distribution device 4; the slurry distribution device 4 comprises a spray head array formed by combining a plurality of spray heads; the spray head array is an interactive mode spray head array with spray heads distributed in a crossed manner; the spray head 4-1 comprises a filtering device 5, a digital flow meter 6, a slurry distribution signal input end 8, a spray head cavity 7, an extrusion device 9, a cache cavity 11 and a flow limiting mechanism 13; the lower end of the extrusion device 9 is made of a transparent material, and an infrared signal transmitter 10 is coated in the transparent material; the upper end of the extrusion device 9 is of a cylindrical solid structure, the lower end of the extrusion device is of a truncated cone-shaped convex solid structure, and the diameter of the truncated cone is smaller the closer to the lower end; the inner wall of the cache cavity 11 is covered with a layer of hydrophobic film; the upper end of the cache cavity 11 is of a cylindrical cavity structure, the inner wall of the lower end of the cache cavity is matched with the lower end of the truncated cone-shaped convex solid structure of the extrusion device 9 and is of a concave truncated cone structure, and the diameter of the truncated cone-shaped cavity is smaller as the cache cavity is closer to the lower end; the flow limiting mechanism 13 comprises a telescopic baffle 15 and a flushing device 16; the upper end of the telescopic baffle 15 is made of transparent silica gel, and the transparent silica gel is coated with an infrared signal receiver 14 for receiving an infrared signal sent by an infrared signal transmitter 10 in the lower end of the extrusion device 9; a plurality of water outlet holes are distributed at the upper end of the washing device 16; the telescopic baffle 15 and the flushing device 16 are both of cuboid structures; the filtering device 5 is a screen mesh with the mesh number of 200 meshes;

the basic digital slurry distribution system has the working process as follows: when a transmission belt 2 on a frame 1 bears a rock plate blank 3 and moves to the lower end of a slurry distribution device 4, a computer control system drives the slurry distribution device 4 to distribute slurry on the surface of the rock plate blank 3 according to an input preset slurry distribution draft, slurry is required to be filtered by a filtering device 5 before entering a spray head 4-1 to remove granular aggregates in the slurry so as to prevent the spray head 4-1 from being blocked, then the slurry flows through a digital flow meter 6 and then enters a spray head cavity 7, when the liquid level of the slurry in the spray head cavity 7 is higher than the inlet of a cache cavity 11, the slurry flows into the cache cavity 11, then a slurry distribution signal input end 8 receives a digital signal from the computer control system to drive an extrusion device 9 to work, the extrusion device 9 starts to descend and enters the cache cavity 11, a slurry flow limiting mechanism 13 and a telescopic baffle 15 of the flow limiting mechanism 13 are also controlled by the computer control system, the thickness and shape control of the lines printed on the surface of the rock plate blank 3 by the slurry is realized through the adjustment of the opening and closing gaps; when the infrared signal transmitter 10 at the lower end of the extrusion device 9 and the infrared signal receiver 14 at the upper end of the telescopic baffle 15 monitor that the spray head 4-1 is blocked, the spray head 4-1 stops working and enters a cleaning state, at the moment, the telescopic baffle 15 is completely extended, the flushing device 16 is closed, and water outlet flushing is carried out by a water outlet hole at the upper end of the flushing device 16 until the infrared signal transmitter 10 at the lower end of the extrusion device 9 and the infrared signal receiver 14 at the upper end of the telescopic baffle 15 monitor a dredging state, the flushing device 16 is completely extended, the telescopic baffle 15 is closed again and enters a working state again;

H. applying a protective glaze: c, applying protective glaze to the surface of the rock slab blank with the natural texture effect after the slurry is distributed in the step G by adopting a spray disc;

I. and (3) drying again: drying the rock plate blank body with the natural texture effect after the protective glaze is applied in the step H according to a conventional method;

J. and (3) texture recognition: adopting an ultra-high-definition digital camera to identify the digital pulp distribution texture on the surface of the rock plate blank body with the natural texture effect after the re-drying in the step I, and sending a network signal to an ink-jet printer;

K. pattern decoration: the ink-jet printer receives the network signal sent by the ultra-high-definition digital camera, transfers the pattern texture corresponding to the digital pulp distribution texture, and performs ink-jet printing on the surface of the rock plate blank with the natural texture effect after the texture identification in the step J in a positioning manner;

l, firing: firing the rock plate blank with the natural texture effect decorated by the patterns in the step K in a roller kiln at 1200 ℃ for 110min to obtain a rock plate semi-finished product with the natural texture effect;

m, edging: and D, utilizing conventional edging processing equipment to carry out edging treatment on the semi-finished product of the rock plate with the natural texture effect obtained by sintering in the step L to obtain a rock plate finished product with the natural texture effect.

Example 4

A. preparing blank powder by a conventional method for later use;

B. preparing slurry for a basic digital slurry distribution system: weighing mineral raw materials according to the chemical composition of the designed basic type digital slurry distribution system slurry, adding a certain proportion of dispergator, suspending agent and water for ball milling, and preparing the basic type digital slurry distribution system with three chemical compositionsSlurry preparation: the first chemical composition of the slurry for the basic digital slurry distribution system is as follows by weight percent: SiO 2₂ 50%，Al₂O₃ 12%，CaO 15%，MgO 5%，K₂O 3%，Na₂O 1.5%，BaO 7%，ZnO 1%，B₂O₃ 3%，Fe₂O₃≤0.5%，TiO₂The base type digital slurry distribution system slurry has the following chemical compositions in percentage by weight: SiO 2₂ 45%，Al₂O₃ 25%，CaO 7%，MgO 4%，K₂O 0.5%，Na₂O 3%，BaO 4%，ZnO 4%，B₂O₃ 0.5%，Fe₂O₃≤0.5%，TiO₂The sintering temperature of the slurry for the basic digital slurry distribution system is higher than that of the slurry for the first basic digital slurry distribution system, and the slurry can be used for forming a semitransparent matte glaze effect, and the third chemical composition of the slurry for the basic digital slurry distribution system is as follows by weight percent: SiO 2₂ 68%，Al₂O₃ 20%，CaO 0.7%，MgO 0.05%，K₂O 5%，Na₂O 2.5%，ZrO₂ 3%，Fe₂O₃≤0.5%，TiO₂The burning loss is less than or equal to 0.5 percent and less than or equal to 8 percent, the burning temperature of the slurry for the basic digital slurry distribution system is higher, and the slurry can be used for forming the effect of opaque matt porcelain surfaces; the rheological property parameters of the slurry for the three basic digital slurry distribution systems are adjusted to be consistent, and the specific gravity is 1.70g/cm³The flow rate of a 50mL flow cup is 20s, the viscosity is 110 mPa.s, the surface tension is 64mN/m, the Reynolds number is 24.8, the Weber number is 85.2, and the bond number is 0.17;

the basic digital pulp distribution system comprises a computer control system and a pulp distribution device 4; the pulp distribution device 4 comprises a spray head array formed by combining a plurality of spray heads; the spray head array is an embedded mode spray head array formed by double rows of spray heads which are distributed equidistantly and in parallel; the spray head 4-1 comprises a filtering device 5, a digital flow meter 6, a slurry distribution signal input end 8, a spray head cavity 7, an extrusion device 9, a cache cavity 11 and a flow limiting mechanism 13; the lower end of the extrusion device 9 is made of a transparent material, and an infrared signal transmitter 10 is coated in the transparent material; the upper end of the extrusion device 9 is of a cylindrical solid structure, the lower end of the extrusion device is of a truncated cone-shaped convex solid structure, and the diameter of the truncated cone is smaller the closer to the lower end; the inner wall of the cache cavity 11 is covered with a layer of hydrophobic film; the upper end of the cache cavity 11 is of a cylindrical cavity structure, the inner wall of the lower end of the cache cavity is matched with the lower end of the truncated cone-shaped convex solid structure of the extrusion device 9 and is of a concave truncated cone structure, and the diameter of the truncated cone-shaped cavity is smaller as the cache cavity is closer to the lower end; the flow limiting mechanism 13 comprises a telescopic baffle 15 and a flushing device 16; the upper end of the telescopic baffle 15 is made of transparent silica gel, and the transparent silica gel is coated with an infrared signal receiver 14 for receiving an infrared signal sent by an infrared signal transmitter 10 in the lower end of the extrusion device 9; a plurality of water outlet holes are distributed at the upper end of the washing device 16; the telescopic baffle 15 and the flushing device 16 are both of semicircular structures; the filtering device 5 is a screen mesh, and the mesh number of the screen mesh is 325 meshes;

F. applying a protective glaze: c, applying protective glaze to the surface of the rock plate blank with the natural texture effect after the digital slurry distribution in the step E by adopting a glaze spraying cabinet;

G. and (3) drying again: drying the rock plate blank with the natural texture effect after the protective glaze is applied in the step F again according to a conventional method;

H. pattern decoration: according to the requirement of the preset pattern texture, adopting an ink jet printing mode, and printing the pattern texture on the surface of the rock plate blank body with the natural texture effect after drying again in the step G by using an ink jet printing machine;

I. and (3) firing: firing the rock plate blank with the natural texture effect decorated by the patterns in the step H in a roller kiln, wherein the firing temperature is 1210 ℃, and the firing period is 90min, so as to obtain a rock plate semi-finished product with the natural texture effect;

J. edging and polishing: and (3) utilizing conventional edging and polishing processing equipment to carry out edging and polishing treatment on the semi-finished product of the rock plate with the natural texture effect obtained by sintering in the step I to obtain a rock plate finished product with the natural texture effect.

The above embodiments are only for illustrating the technical solution of the present invention and not for limiting the same, although the present invention is described in detail with reference to the preferred embodiments, it should be understood by those of ordinary skill in the art. Modifications to the embodiments of the invention or equivalent substitutions of parts of the technical features can be made without departing from the spirit of the technical solution of the invention, which is to be covered by the technical solution of the invention.

Claims

1. A method of making a rock panel having a natural grain effect, comprising the steps of:

A. preparing blank powder by a conventional method for later use;

B. preparing the slurry for the basic digital slurry distribution system: weighing mineral raw materials according to the chemical composition of the designed slurry for the basic digital slurry distribution system, adding a dispergator, a suspending agent and water in a certain proportion, and carrying out ball milling to prepare the slurry for the basic digital slurry distribution system;

I. edging: d, utilizing conventional edging processing equipment to carry out edging treatment on the semi-finished product of the rock plate with the natural texture effect, which is obtained by sintering in the step H, so as to obtain a finished product of the rock plate with the natural texture effect;

2. The method of claim 1, wherein the slurry for the digital slurry distribution system of the base type in the step B is prepared by adding a colorant into the slurry for the digital slurry distribution system of the base type to prepare a slurry for the digital slurry distribution system of the colored base type.

3. The method of manufacturing a rock panel having a natural grain effect as set forth in claim 1, wherein the slurry for the basic type digital grouting system in the step B has 3 chemical compositions: the first chemical composition of the slurry for the basic digital slurry distribution system is as follows by weight percent: SiO 2₂ 45%~50%，Al₂O₃ 12%~16%，CaO 11%~15%，MgO 5%~8%，K₂O 1.5%~3%，Na₂O 1.5%~3%，BaO 3%~7%，ZnO 1%~3%，B₂O₃ 0.5%~3%，Fe₂O₃ ≤0.5%，TiO₂The sintering temperature of the slurry for the basic digital slurry distribution system with the first chemical composition is lower and is used for forming a transparent bright glaze effect; the second chemical composition of the slurry for the basic digital slurry distribution system is as follows by weight percent: SiO 2₂ 43%~49%，Al₂O₃ 20%~25%，CaO 5%~10%，MgO 1.5%~4%，K₂O 0.5%~2%，Na₂O 1.5%~3%，BaO 4%~8%，ZnO 1.5%~4%，B₂O₃ 0.5%~3%，Fe₂O₃ ≤0.5%，TiO₂The sintering temperature of the slurry for the basic digital slurry distribution system with the second chemical composition is higher than that of the slurry for the first basic digital slurry distribution system, and the slurry is used for forming a semitransparent matte glaze effect; the third chemical composition of the slurry for the basic digital slurry distribution system is as follows by weight percent: SiO 2₂ 62%~68%，Al₂O₃ 20%~23%，CaO 0.1%~0.7%，MgO 0.05%~0.2%，K₂O 3.5%~5%，Na₂O 2.5%~3.5%，ZrO₂ 1%~3%，Fe₂O₃ ≤0.5%，TiO₂The burning loss is less than or equal to 0.5 percent, the burning loss is less than or equal to 8 percent, the burning temperature of the slurry for the basic digital slurry distribution system with the third chemical composition is higher, and the slurry is used for forming the effect of opaque matt porcelain surface.

4. The method for manufacturing a rock laminate having a natural texture effect as claimed in claim 1, wherein the specific gravity of the slurry for the basic digital slurry distribution system in the step B is 1.20 to 1.85g/cm³The flow rate of the 50mL flow cup is 10 to 25s, the viscosity is 40 to 500 mPas, and the surface tension is 50 to 70 mN/m.

5. The method for manufacturing a rock laminate having a natural texture effect as claimed in claim 1, wherein the Reynolds number of the slurry for the basic digital grouting system in the step B is 5 to 50, the Weber number is 70 to 130, and the Bunde number is 0.12 to 0.25.

6. A method of manufacturing a rock panel having a natural grain effect as claimed in claim 1 wherein a step of applying primer is added between steps D and E.

7. The method of manufacturing a rock panel having a natural grain effect as claimed in claim 6, wherein the primer is applied using one of a shower and a spray booth.

8. The method as claimed in claim 1, wherein the basic digital grout distribution system of step E comprises a computer control system and a grout distribution device; the slurry distribution device comprises a spray head array formed by combining a plurality of spray heads; the sprayer comprises a filtering device, a digital flowmeter, a slurry distribution signal input end, a sprayer cavity, an extrusion device, a cache cavity and a current limiting mechanism; the lower end of the extrusion device is made of a transparent material, and the infrared signal generator is coated in the transparent material; the upper end of the extrusion device is of a cylindrical solid structure, and the lower end of the extrusion device is of a circular truncated cone-shaped convex solid structure; the inner wall of the cache cavity is covered with a layer of hydrophobic film; the upper end of the cache cavity is of a cylindrical cavity structure, the lower end of the cache cavity is of a truncated cone-shaped cavity structure, and the inner wall of the cache cavity is matched with the lower end of a truncated cone-shaped convex solid structure of the extrusion device; the flow limiting mechanism comprises a telescopic baffle and a flushing device; the upper end of the telescopic baffle is made of transparent silica gel, and the transparent silica gel is coated with an infrared signal receiver for receiving an infrared signal sent by an infrared signal generator in the lower end of the extrusion device; and a plurality of water outlet holes are distributed at the upper end of the flushing device.

9. The method of manufacturing a rock panel having a natural grain effect of claim 8, wherein the computer control system is configured to control the slurry distribution device to distribute slurry in a predetermined grain.

10. The method of manufacturing a rock panel having a natural grain effect of claim 8, wherein the nozzle array is a single mode nozzle array formed of a single row of nozzles arranged in parallel at equal distances.

11. The method of manufacturing a rock panel having a natural grain effect of claim 8, wherein said array of spray heads is a mosaic pattern array of spray heads formed of two rows of spray heads distributed in parallel at equal distances.

12. The method of manufacturing a rock panel having a natural grain effect of claim 8, wherein the nozzle array is an alternating pattern nozzle array in which nozzles are distributed in a cross-over pattern.

13. The method of manufacturing a rock panel having a natural grain effect of claim 8, wherein said filtering means is a screen.

14. The method of manufacturing a rock panel having a natural grain effect of claim 13, wherein the mesh number of the screen is 50-600 mesh.

15. The method of making a rock panel having a natural grain effect of claim 14, wherein the mesh size is 200-325 mesh.

16. The method of manufacturing a natural grain effect rock panel of claim 8, wherein said filter means is a honeycomb ceramic.

17. The method of manufacturing a rock panel having a natural grain effect as claimed in claim 8, wherein the digital flow meter displays the flow rate of the slurry flowing into the nozzle in real time and feeds back the same to the computer control system, and the computer control system adjusts the flow rate of the slurry.

18. The method of making a natural grain effect rock panel of claim 8, wherein said compression means is a clear silicone material.

19. The method for manufacturing a rock panel having a natural grain effect as claimed in claim 8, wherein said hydrophobic film is mixed with a high hardness substance of diamond sand type.

20. The method of manufacturing a rock panel having a natural grain effect as claimed in claim 8, wherein the retractable baffle and the flushing means are each one of a rectangular parallelepiped structure and a semicircular structure.

21. The method of manufacturing a rock panel having a natural grain effect as claimed in claim 20, wherein when said retractable baffle and said flushing means are of rectangular parallelepiped configuration, the restriction means is of cross configuration; when the telescopic baffle and the flushing device are both of semicircular structures, the formed flow limiting mechanism is of a petal-shaped structure.

22. The method of manufacturing a rock panel having a natural grain effect as claimed in claim 8, wherein the opening and closing gap of the retractable barrier is continuously controlled from 0% to 100%.

23. The method of manufacturing a rock panel having a natural grain effect as set forth in claim 8, wherein said slurry distribution system is operated as follows: when the transmission belt bears the rock plate blank and moves to the lower end of the pulp distribution device, the computer control system drives the pulp distribution device to distribute pulp on the surface of the rock plate blank according to the input preset pulp distribution draft, pulp is required to be filtered by the filtering device before entering the spray head, granular aggregates in the pulp are removed, so as to prevent the nozzle from being blocked, then flows through the digital flowmeter, and then enters the nozzle cavity, when the liquid level of the slurry in the nozzle cavity is higher than the inlet of the cache cavity, namely flows into the buffer cavity, then the pulp distribution signal input end receives a digital signal from a computer control system to drive the extrusion device to work, the extrusion device begins to descend and enters the buffer cavity, the slurry is extruded out of the flow limiting mechanism, the telescopic baffle plate of the flow limiting mechanism is also controlled by the computer control system, controlling the thickness and the shape of lines printed on the surface of the rock plate blank by the slurry through adjusting the opening and closing gaps; when the infrared signal generator at the lower end of the extrusion device and the infrared signal receiver at the upper end of the telescopic baffle plate monitor that the spray head is blocked, the spray head stops working immediately and enters a cleaning state, at the moment, the telescopic baffle plate is completely stretched out, the flushing device is closed and is flushed by water outlet holes at the upper end of the flushing device, until the infrared signal generator at the lower end of the extrusion device and the infrared signal receiver at the upper end of the telescopic baffle plate monitor the dredging state, the flushing device is completely stretched out, the telescopic baffle plate is closed again, and the spray head enters the working state again.

24. A method of manufacturing a rock panel having a natural grain effect as claimed in claim 1 wherein a step of applying a protective glaze is added between said steps E and F.

25. The method as claimed in claim 1, wherein the step G of pattern decoration is performed by using a conventional inkjet printer, and the inkjet printer prints the pattern on the surface of the rock blank with natural texture effect after drying again in the step F.

26. The method of manufacturing a rock plate with natural texture effect as claimed in claim 1, wherein the pattern decoration in the step G is performed by means of penetrating ink-jet printing, and the ink-jet printer prints the pattern texture on the surface of the rock plate blank with natural texture effect after drying again in the step F.

27. The method of manufacturing a rock plate having a natural texture effect as claimed in claim 25 or 26, wherein a step of texture recognition is added between the step F and the step G, the texture recognition is to use an ultra-high-definition digital camera to recognize the digital slurry texture on the surface of the rock plate blank having the natural texture effect after the re-drying in the step F, and send a network signal to an inkjet printer, the inkjet printer re-retrieves the pattern texture corresponding to the digital slurry texture, and the positioning inkjet printing pattern decoration is performed on the surface of the rock plate blank having the natural texture effect after the re-drying in the step F.

28. The method for manufacturing a rock plate with natural texture effect as claimed in claim 1, wherein the step G is characterized in that the pattern decoration is implemented by screen printing, and the screen printing machine prints the pattern texture on the surface of the rock plate blank with natural texture effect after drying again in the step F.

29. The method as claimed in claim 1, wherein the step G of decorating the pattern is performed by rubber roll printing, and the rubber roll printer prints the pattern on the surface of the natural-textured rock blank after the step F of drying again.

30. The method of manufacturing a rock panel having a natural grain effect as set forth in claim 1, wherein a polishing process is applied after the step I.

31. A natural grain effect rock panel produced by the method of any one of claims 1 to 30.