阅读说明：本技术 一种用于陶瓷大板的超平釉及纯色陶瓷大板的制备工艺 (Preparation process of super-flat glaze and pure-color ceramic large plate for ceramic large plate ) 是由 张代兰 黄旺明 董金 袁静 阮红军 于 2021-09-30 设计创作，主要内容包括：本发明公开了一种用于陶瓷大板的超平釉及纯色陶瓷大板的制备工艺,超平釉包括按重量份计的以下有效组分：硬质料53-94份；软质料20-35份；硅酸锆0-2份；辅剂0.3-1份；硬质料包括精选砂、白砂和钠砂；软质料包括高铝土；制备工艺为首先分别制备坯体层及超平釉,再将上述坯体层经过釉线施釉-数码喷墨-窑炉烧成-磨边步骤,得到纯色陶瓷大板；本发明的超平釉使用精选砂、白砂、钠砂和高铝土等坯用原料,使坯釉两者之间的原料性能接近,熔融排气时间接近,因而对于坯体结合度高于普通釉料,整体配方熔融排气性能好,釉面平整度高于普通釉料产品,相对于普通釉料,釉面手感、平整度、砖型、硬度对比普通釉料均有提升。(The invention discloses a preparation process of super-flat glaze for a ceramic large plate and a pure-color ceramic large plate, wherein the super-flat glaze comprises the following effective components in parts by weight: 53-94 parts of hard material; 20-35 parts of soft material; 0-2 parts of zirconium silicate; 0.3-1 part of an auxiliary agent; the hard material comprises selected sand, white sand and sodium sand; the soft material comprises high alumina; the preparation process comprises the steps of firstly preparing a body layer and super-flat glaze respectively, and then carrying out glaze line glazing, digital ink jet, kiln firing and edge grinding on the body layer to obtain a pure-color ceramic large plate; the ultra-flat glaze uses the raw materials for the blanks such as the selected sand, the white sand, the sodium sand, the high alumina and the like, so that the performances of the raw materials of the blank glaze and the high alumina are close, and the melting and exhausting time is close, therefore, the blank combination degree is higher than that of the common glaze, the melting and exhausting performance of the whole formula is good, the glaze surface smoothness is higher than that of the common glaze product, and compared with the common glaze, the hand feeling, the smoothness, the brick shape and the hardness of the glaze surface are improved.)

1. The super-flat glaze for the ceramic large plate is characterized by comprising the following effective components in parts by weight:

the hard material comprises selected sand, white sand and sodium sand; the soft material comprises high alumina.

2. The ultra-flat glaze for ceramic large plates according to claim 1, characterized by comprising the following effective components in parts by weight:

3. the ultra-flat glaze for ceramic large plates according to claim 1, wherein the hard material comprises, in parts by weight:

4. the ultra-flat glaze for ceramic large plates according to claim 1, wherein the soft material comprises, in parts by weight:

5-10 parts of air knife kaolin;

10-15 parts of calcined kaolin;

5-10 parts of high alumina.

5. The ultra-flat glaze for ceramic panels as claimed in claim 1, wherein the auxiliary agents include sodium carboxymethyl cellulose, a dispersant for glaze and a debonder; the dispergator is sodium tripolyphosphate; the dispersing agent for the glaze is a liquid dispergator.

6. A preparation process of an ultra-flat glaze for a pure-color ceramic large plate is characterized by comprising the following steps:

s1, preparing a blank: putting raw material components of the green body into a ball mill, uniformly mixing to obtain slurry, sieving the slurry, ageing, removing impurities, performing spray drying to obtain powder, performing compression molding on the powder, and drying in a drying kiln to obtain a green body layer;

s2, preparing the ultra-flat glaze: the preparation method comprises the following steps of (1) mixing the following effective components in parts by weight:

sequentially carrying out batching and ball throwing, raw material ball milling, glaze slip detection, slip discharging, iron removing and sieving, and storing and aging for later use to obtain the super flat glaze;

the hard material comprises white sand, sodium sand and selected sand; the soft material comprises high alumina;

and S3, glazing the blank layer through a glaze line, carrying out digital ink jet, firing in a kiln, and carrying out edge grinding to obtain the ceramic large plate.

7. The process for preparing the solid-color ceramic large plate according to claim 6, wherein during the preparation of the ultra-flat glaze, the glaze pigment is added and stirred for half an hour after the ultra-flat glaze is aged.

8. The process for preparing a solid color ceramic panel according to claim 7, wherein the amount of the glaze pigment is 0 to 5 parts.

9. The preparation process of the pure-color ceramic large plate as claimed in claim 6, wherein in the preparation process of the ultra-flat glaze, the fineness of the glaze slip is 0.6-0.8g of 325-mesh screen residue, and the flow rate is 60-120 s measured by a four-viscosity cup.

10. The process for preparing the pure-color ceramic large plate according to claim 6, wherein the thickness of the ceramic large plate is 2-20 mm, and the surface area is not less than 1.62m²。

Technical Field

The invention relates to a preparation process of an ultra-flat glaze and a pure-color ceramic large plate for a ceramic large plate, belonging to the technical field of building materials.

Background

The architectural ceramic products are developed to the present, the surface decoration technology is very abundant, and besides the basic easy-to-clean performance of the decorative glaze on the ceramic blank is maintained, the physical performance of the ceramic products is often required to be improved through the glaze. In recent years, ceramic large plates have become hot spots in high-end markets of ceramic building industry due to the characteristics of rich color, natural texture, strong continuity, rich layering texture and the like. The ceramic large plate is not only used for floor tiles, but also can be used as a novel material for cabinet panels and kitchen and bathroom table tops, and can be widely applied to deep processing and customized products; besides the breakthrough of the specification, the texture and comprehensive application solution is the main innovative direction.

The size of the ceramic large plate is far larger than that of a common ceramic tile, so that the difficulty in solving the problems of flatness, bubbles, cracking and the like of the tile surface in the preparation process is higher than that of the common ceramic tile, particularly, the pure-color ceramic large plate is one of high-end ceramics in the world, can be used as an engineering external wall plate, an indoor floor plate, a high-end villa, a large commercial square and the like, and is wide in application range.

Accordingly, there are deficiencies in the art and improvements and developments are needed.

Disclosure of Invention

In order to overcome the defects of the prior art, the invention aims to provide the ultra-flat glaze for the large ceramic plate, the whole formula has good melting and exhausting performance, and the glaze surface smoothness, the glaze hand feeling, the brick shape and the hardness of the prepared pure-color large plate are improved compared with those of the common glaze.

The second purpose of the invention is to provide a preparation process for preparing a pure-color ceramic large plate by using the ultra-flat glaze.

The first purpose of the invention can be achieved by adopting the following technical scheme: the super-flat glaze for the ceramic large plate comprises the following effective components in parts by weight:

the hard material comprises selected sand, white sand and sodium sand; the soft material comprises high alumina.

Further, the composition comprises the following effective components in parts by weight:

further, the hard material comprises the following components in parts by weight:

further, the soft material comprises the following components in parts by weight:

5-10 parts of air knife kaolin;

10-15 parts of calcined kaolin;

5-10 parts of high alumina.

Further, the auxiliary agents comprise sodium carboxymethyl cellulose, a glaze dispersant and a debonder; the dispergator is sodium tripolyphosphate; the dispersing agent for the glaze is a liquid dispergator.

The second purpose of the invention can be achieved by adopting the following technical scheme:

a preparation process of a pure-color ceramic large plate comprises the following steps:

s1, preparing a blank: putting raw material components of the green body into a ball mill, uniformly mixing to obtain slurry, sieving the slurry, ageing, removing impurities, performing spray drying to obtain powder, performing compression molding on the powder, and drying in a drying kiln to obtain a green body layer;

s2, preparing the ultra-flat glaze: the preparation method comprises the following steps of (1) mixing the following effective components in parts by weight:

sequentially carrying out batching and ball throwing, raw material ball milling, glaze slip detection, slip discharging, iron removing and sieving, and storing and aging for later use to obtain the super flat glaze; the hard material comprises white sand, sodium sand and selected sand; the soft material comprises high alumina;

and S3, glazing the blank layer through a glaze line, carrying out digital ink jet, firing in a kiln, and carrying out edge grinding to obtain the ceramic large plate.

Further, in the preparation process of the ultra-flat glaze, the glaze is added with the pigment for stirring for half an hour after the ultra-flat glaze is aged.

Furthermore, the addition amount of the glaze pigment is 0-5 parts.

Further, in the preparation process of the ultra-flat glaze, the fineness of glaze slip is 0.6-0.8g of 325-mesh screen residue, and the flow rate is 60-120 s measured by a four-viscosity cup.

Further, the thickness of the ceramic large plate is 2-20 mm, and the surface area is not less than 1.62m²。

Compared with the prior art, the invention has the beneficial effects that:

1. the ultra-flat glaze uses the raw materials for the blanks such as the selected sand, the white sand, the sodium sand, the high alumina and the like, so that the performances of the raw materials of the blank glaze and the high alumina are close, and the melting and exhausting time is close, therefore, the blank combination degree is higher than that of the common glaze, the melting and exhausting performance of the whole formula is good, the glaze surface smoothness is higher than that of the common glaze product, and compared with the common glaze, the hand feeling, the smoothness, the brick shape and the hardness of the glaze surface are improved;

2. meanwhile, the invention effectively solves the problems that the existing pure-color ceramic plate is easy to generate cracks, holes and color difference in the production process, and the appearance is affected because the effect of consistent color between the surface and the inside is difficult to achieve.

3. The selected sand, the white sand, the sodium sand and the high alumina are added into the super-flat glaze, the adding amount of the simple substance quartz is reduced, the problems that the initial melting point is high and difficult to melt in the early stage and the melting point is difficult to flatten in the later stage due to excessive quartz addition can be avoided, so that the melting point of the glaze is further reduced, the melting point of the glaze is reduced, the hardness of the glaze is higher, and the brick shape is more excellent;

4. according to the invention, by improving the component proportion of the super-flat glaze, the prepared ceramic large plate has excellent performance indexes such as flatness, hardness, brick shape and the like, and is good in economic benefit and suitable for large-scale popularization.

Detailed Description

The following detailed description is provided for the embodiments of the present invention, so that how to apply the technical means to solve the technical problems and achieve the technical effects can be fully understood and implemented. Unless otherwise indicated, the techniques employed in the examples are conventional and well known to those skilled in the art, and the reagents and products employed are also commercially available. Various procedures and methods not described in detail are conventional methods well known in the art, and all reagents are commonly available commercially.

The invention provides an ultra-flat glaze for a ceramic large plate, which comprises the following effective components in parts by weight:

the hard material comprises selected sand, white sand and sodium sand; the soft material comprises high alumina.

As a further preferable scheme, the ultra-flat glaze for the ceramic large plate comprises the following effective components in parts by weight:

as a further preferable scheme, the hard material comprises the following components in parts by weight:

as a further preferable scheme, the soft material comprises the following components in parts by weight:

5-10 parts of air knife kaolin;

10-15 parts of calcined kaolin;

5-10 parts of high alumina.

As a further preferred scheme, the auxiliary agents comprise sodium carboxymethyl cellulose, a glaze dispersing agent and a debonder; the dispergator is sodium tripolyphosphate; the dispersing agent for the glaze is a liquid dispergator.

In the formula of the invention, as the raw materials for the green body such as the selected sand, the white sand, the high-white sodium sand, the high-alumina and the like are introduced, the properties of the raw materials are close, the adaptability of the green body glaze is improved, the melting and exhausting time is close, the melting property is better, the matching degree is high, the melting points of the green body layer and the glaze layer are consistent with the crystal phase conversion temperature, and the problems of air bubbles and flatness of the brick surface can be well solved.

In the formula of the invention, high-silicon raw materials for the blank such as selected sand, white sand and the like are added, so that quartz is added to avoid the adjustment of the glossiness by glaze, the melting point of the glaze is reduced, and the brick surface is smoother. The quartz is difficult to melt at the early stage and difficult to melt at the later stage due to the high initial melting point of the quartz, and the expansion coefficients and the initial melting points of a green body layer and a glaze layer are closer by adopting a large amount of green body raw materials in the ultra-flat glaze formula, so that the brick shape and bubbles can be effectively controlled.

In the formula of the invention, the raw materials such as potassium feldspar, albite and the like are added to mainly play a role in high-temperature dissolution, increase the high-temperature liquid phase, improve the homogenization degree of the glaze layer and enable the glaze surface to be smoother.

In the formula of the invention, the sodium tripolyphosphate mainly plays a role of a ceramic debonder, so that the fluidity of the glaze slurry is increased, and the ceramic performance is improved.

The liquid debonder has the characteristics of better slurry stability, higher slurry flow rate, higher slurry proportion, more uniform particle distribution and the like, and is particularly suitable for a refractory debonder formula system with high aluminum and high viscosity; in the formula of the invention, the liquid debonder is added to be matched with auxiliary agents such as sodium tripolyphosphate and the like for use, so that a synergistic effect is generated, the ceramic glaze slip can be mainly diluted, the thixotropy of the ceramic glaze slip is reduced, the flow rate reduction caused by the thixotropy in the storage process is prevented, the glaze slip performance is improved, and the ceramic glaze slip can be effectively prevented from precipitating.

As a further preferable scheme, the liquid debonder is a liquid debonder with the model number FG-101B, which is purchased from Guangdong novel materials Co., Ltd, of Foshan city.

As a further preferred embodiment, the sodium carboxymethyl cellulose is selected from huawei cellulose limited.

The ultra-flat glaze uses the raw materials for the blanks such as the selected sand, the white sand, the sodium sand, the high alumina and the like, so that the performances of the raw materials of the blank glaze and the high alumina are close, and the melting and exhausting time is close, therefore, the blank combination degree is higher than that of the common glaze, the melting and exhausting performance of the whole formula is good, the glaze surface smoothness is higher than that of the common glaze product, and compared with the common glaze, the hand feeling, the smoothness, the brick shape and the hardness of the glaze surface are improved;

in addition, the selected sand, the white sand, the sodium sand and the high alumina are added into the super-flat glaze, the adding amount of the simple substance quartz is reduced, and the problems that the initial melting point is high and difficult to melt in the early stage and the later stage is difficult to melt and level due to excessive quartz addition can be avoided, so that the melting point of the glaze is further reduced, the melting point of the glaze is reduced, the hardness of the glaze is higher, and the brick shape is more excellent.

The invention also provides a preparation process of the super-flat glaze for preparing the pure-color ceramic large plate, which comprises the following steps:

s1, preparing a blank: putting raw material components of the green body into a ball mill, uniformly mixing to obtain slurry, sieving the slurry, ageing, removing impurities, performing spray drying to obtain powder, performing compression molding on the powder, and drying in a drying kiln to obtain a green body layer;

s2, preparing the ultra-flat glaze: the preparation method comprises the following steps of (1) mixing the following effective components in parts by weight:

sequentially carrying out batching and ball throwing, raw material ball milling, glaze slip detection, slip discharging, iron removing and sieving, and storing and aging for later use to obtain the super flat glaze;

the hard material comprises white sand, sodium sand and selected sand; the soft material comprises high alumina;

and S3, glazing the blank layer through a glaze line, carrying out digital ink jet, firing in a kiln, and carrying out edge grinding to obtain the ceramic large plate.

As a further preferable scheme, in the preparation process of the ultra-flat glaze, the glaze pigment is added and stirred for half an hour after the ultra-flat glaze is aged.

More preferably, the addition amount of the glaze coloring material is 0 to 5 parts; the glaze pigment was purchased from Huadu ceramic color glaze, Inc., of Foshan City.

As a further preferable scheme, in the preparation process of the ultra-flat glaze, the fineness of glaze slip is 0.6-0.8g of 325-mesh screen residue, and the flow rate is 60-120 s measured by a four-viscosity cup.

As a further preferable scheme, the thickness of the pure-color ceramic big plate is 2-20 mm, and the surface area is not less than 1.62m²。

The invention is further illustrated below with reference to specific examples:

an ultra-flat glaze for ceramic large plates comprises the following effective components in parts by weight as shown in Table 1:

TABLE 1 effective Components

The preparation process of the super flat glaze comprises the steps of sequentially carrying out material proportioning and ball throwing on the effective components, carrying out raw material ball milling, carrying out glaze slurry detection, discharging slurry, removing iron, sieving, storing and aging for later use, and obtaining the super flat glaze.

Wherein in the preparation process of the ultra-flat glaze, the fineness of the glaze slip is 0.6-0.8g of 325-mesh screen residue, and the flow rate is 60-120 s measured by a four-viscosity cup.

Examples 1-3 and comparative examples 1-2:

the effective component weight parts of examples 1-3 and comparative examples 1-2 are shown in table 2:

TABLE 2 effective component parts by weight of examples and comparative examples

The preparation process of the super flat glaze comprises the steps of sequentially carrying out material proportioning and ball throwing on the effective components, carrying out raw material ball milling, carrying out glaze slurry detection, discharging slurry, removing iron, sieving, storing and aging for later use, and obtaining the super flat glaze.

Wherein in the preparation process of the ultra-flat glaze, the fineness of the glaze slip is 0.6-0.8g of 325-mesh screen residue, and the flow rate is 60-120 s measured by a four-viscosity cup; adding glaze pigment and stirring for half an hour after the mixture is aged; the addition amount of the glaze pigment is 0-5 parts.

The examples and comparative examples were tested:

TABLE 3 test results of examples and comparative examples

According to the results of the above-mentioned tests, in examples 1-3 and comparative example 1 of the present invention, since the raw materials for the green body such as the selected sand, the white sand, the high white sodium sand, the high alumina, etc. are introduced, the raw material properties between the two are close, the adaptability of the green body glaze is improved, the melting exhaust time is close, the melting ratio is good, the matching degree is high, the melting points of the green body layer and the glaze layer are consistent with the crystal phase conversion temperature, and the problems of the air bubbles and the flatness of the brick surface can be well solved; high-silicon raw materials for the blanks such as the selected sand, the white sand and the like are added, so that the condition that the glaze is added for adjusting the glossiness is avoided, the melting point of the glaze is reduced, and the surface of the brick is smoother. The quartz is difficult to melt at the early stage and difficult to melt at the later stage due to the high initial melting point of the quartz, and the expansion coefficients and the initial melting points of a green body layer and a glaze layer are closer by adopting a large amount of green body raw materials in the ultra-flat glaze formula, so that the brick shape and bubbles can be effectively controlled.

In comparative example 2, the above-mentioned raw materials for green bodies such as beneficiated sand, white sand, high-white sodium sand, high alumina were not added, and the produced ceramic slabs were inferior in performance indexes such as flatness, brick shape, antifouling property, etc., to those of the ceramic slabs of examples 1 to 3 of the present invention. In addition, in the comparative example 2, the raw materials such as calcined alumina, wollastonite and barium carbonate are added to replace the raw materials of the blank glaze such as the selected sand and the white sand, the applicability and the exhaust of the blank glaze are poor, the melting points and the crystal phase conversion temperatures of the blank layer and the glaze layer are difficult to be consistent, and compared with the embodiment of the invention, the brick surface has poor bubbles and flatness. The invention can also be obtained by comparison, because the raw materials for the green body such as the selected sand, the white sand, the high-white sodium sand, the high-alumina and the like are introduced, the performance of the raw materials between the selected sand and the white sand is approximate, the adaptability of the green body glaze is improved, the melting and exhausting time is approximate, the melting property is better, the matching degree is high, the melting points of the green body layer and the glaze layer are consistent with the crystal phase conversion temperature, and the problems of air bubbles and flatness of the brick surface can be well solved.

In comparative example 1, the performance of the glaze slip is not qualified due to the fact that no glaze dispersant is added, and the subsequent glaze pouring process is directly affected, because the liquid debonding agent is added and can be used in cooperation with auxiliary agents such as sodium tripolyphosphate and the like to generate a synergistic effect, the liquid debonding agent can mainly dilute the ceramic glaze slip, reduce the thixotropy of the ceramic glaze slip, prevent the flow rate caused by the thixotropy in the storage process from being slowed down, improve the performance of the glaze slip, and simultaneously effectively prevent the ceramic glaze slip from being precipitated.

Various other changes and modifications to the above-described embodiments and concepts will become apparent to those skilled in the art from the above description, and all such changes and modifications are intended to be included within the scope of the present invention as defined in the appended claims.