阅读说明：本技术 一种用于陶瓷砖的超平釉、陶瓷砖及其制造方法 (Super-flat glaze for ceramic tiles, ceramic tiles and manufacturing method of ceramic tiles ) 是由 盛正强 王永强 欧志勇 曹端旭 古战文 于 2020-12-11 设计创作，主要内容包括：本发明公开了一种用于陶瓷砖的超平釉、陶瓷砖及其制造方法,超平釉以质量百分比计包括：有机溶剂20％～40％；无机陶瓷粉体40％～70％；高分子有机分散剂8％～25％。通过将无机陶瓷粉体以有机溶剂分散,以有机溶剂替代了传统釉浆中的水介质,可使超平釉覆盖在油性装饰油墨之上,避免装饰油墨之上出现缺釉；通过在超平釉中添加高分子有机分散剂和有机溶剂,防止超细粉体粒子产生二次团聚絮凝,降低釉浆粘度,提高釉浆流动性能,提高超平釉中的固含量,形成均匀分散的釉料,在装饰油墨上形成致密且细腻的釉层,使得超平釉层不需要抛光工艺,也可以平整分布,避免出现波纹,提升陶瓷砖成品优等率。(The invention discloses an ultra-flat glaze for ceramic tiles, the ceramic tiles and a manufacturing method thereof, wherein the ultra-flat glaze comprises the following components in percentage by mass: 20 to 40 percent of organic solvent; 40 to 70 percent of inorganic ceramic powder; 8 to 25 percent of macromolecular organic dispersant. By dispersing the inorganic ceramic powder with an organic solvent and replacing a water medium in the traditional glaze slip with the organic solvent, the super-flat glaze can cover the oily decorative ink, and the glaze shortage on the decorative ink is avoided; by adding the high-molecular organic dispersant and the organic solvent into the super-flat glaze, secondary agglomeration and flocculation of superfine powder particles are prevented, the viscosity of the glaze slip is reduced, the flowing property of the glaze slip is improved, the solid content of the super-flat glaze is improved, uniformly dispersed glaze is formed, and a compact and fine glaze layer is formed on decorative ink, so that the super-flat glaze layer does not need a polishing process, can be distributed flatly, avoids ripples, and improves the goodness rate of finished ceramic tiles.)

1. An ultra-flat glaze for ceramic tiles, characterized in that the ultra-flat glaze comprises, in mass percent:

20 to 40 percent of organic solvent;

40 to 70 percent of inorganic ceramic powder;

8 to 25 percent of macromolecular organic dispersant.

2. The ultra-flat glaze for ceramic tiles as claimed in claim 1, wherein the raw materials of the inorganic ceramic powder comprise, in weight fraction:

1-3 parts of zinc oxide; 8-12 parts of barium carbonate; 30-50 parts of feldspar; 6-15 parts of calcined talc; 6-15 parts of a fused block particle; 6-15 parts of kaolin; 6-8 parts of calcined kaolin; 6-10 parts of calcium carbonate.

3. The ultra-flat glaze for ceramic tiles as claimed in claim 2, wherein the raw materials of the inorganic ceramic powder comprise, by weight:

2 parts of zinc oxide; 12 parts of barium carbonate; 42 parts of feldspar; 10 parts of calcined talc; 10 parts of a fused block particle; 8 parts of kaolin; 8 parts of calcined kaolin; 8 parts of calcium carbonate.

4. The ultra-flat glaze for ceramic tiles as claimed in claim 1, wherein the chemical composition of the inorganic ceramic powder comprises, in mass percent:

SiO₂ 45％～65％；Al₂O₃ 10％～20％；Fe₂O₃ 0～0.5％；CaO 4％～10％；MgO 3％～10％；K₂O 0～2％；Na₂O 4％～8％；ZnO 1％～3％；BaO 8％～15％。

5. the ultra-flat glaze for ceramic tiles as claimed in claim 4, wherein the chemical composition of the inorganic ceramic powder comprises, in mass percent:

SiO₂ 55.47％；Al₂O₃ 16.48％；Fe₂O₃ 0.23％；CaO 6.37％；MgO 3.90％；K₂O 0.47％；Na₂O 4.69％；ZnO 2.17％；BaO 10.22％。

6. the ultra-flat glaze for ceramic tiles according to claim 1, wherein the organic solvent has a viscosity of 2 to 8 mPa-S at 40 ℃;

the organic solvent comprises isopropyl laurate, isooctyl laurate, isopropyl myristate, isooctyl palmitate, isopropyl palmitate, dipropylene glycol methyl ether acetate, tripropylene glycol methyl ether, tripropylene glycol monobutyl ether, isomeric tridecanol polyoxyethylene ether or white oil;

the high molecular organic dispersant comprises polyester fatty acid amide;

the solid content of the super flat glaze is 65-75 percent; the glazing amount of the ultra-flat glaze is 260-420 g/m²(ii) a The fluidity of the ultra-flat glaze is 30-40 seconds; the fineness of the glaze slip of the ultra-flat glaze is 0.3-0.5% of the screen residue of a 325-mesh sieve.

7. A method of making a ceramic tile, comprising:

pressing, molding and drying the inorganic ceramic powder to obtain a plate-shaped ceramic tile blank;

applying a ground coat or a cover coat on the plate-shaped ceramic tile blank body through a spraying or showering process and drying to obtain a ground coat layer or a cover coat layer;

digitally printing decorative patterns on the ground glaze layer or the surface glaze layer by an ink jet printer to obtain a decorative pattern layer;

applying the super-flat glaze according to any one of claims 1 to 6 on the decorative pattern layer through a bell jar glaze sprayer to obtain a super-flat glaze layer;

and putting the ceramic tiles into a kiln for sintering to obtain the ceramic tiles.

8. The method of manufacturing ceramic tiles as claimed in claim 7,

the solid content of the super flat glaze is 71 percent;

the glazing amount of the ultra-flat glaze is 360g/m²；

The fluidity of the ultra-flat glaze is 36 seconds;

the fineness of the glaze slip of the ultra-flat glaze is 0.32 percent of the screen residue of a 325-mesh sieve.

9. Ceramic tile, characterized in that it is manufactured by a method for manufacturing ceramic tiles according to any one of claims 7 to 8.

10. The ceramic tile as claimed in claim 9, which comprises, in order from bottom to top: a ceramic brick body layer, a ground glaze layer or a surface glaze layer, a decorative pattern layer and an ultra-flat glaze layer.

Technical Field

The invention relates to the field of ceramic tile production, in particular to an ultra-flat glaze for ceramic tiles, a ceramic tile and a manufacturing method thereof.

Background

The surface decoration technology of building ceramic tiles is very abundant today, and besides the basic easy-to-clean performance of the decorative glaze on ceramic blanks, various patterns and colors on the surface of the glaze are often required to be decorated to improve the decoration performance of the ceramic tiles. In recent years, with the application and popularization of digital ink-jet technology, ink-jet decoration technology has become the main decoration method for ceramic tile pattern colors. The natural stone material has natural and fine decorative texture, rich color and distinct gradation. The decorative pattern of the digital ink-jet ceramic tile mainly simulates the texture of natural stone, and the fidelity or simulation degree of the ceramic tile decoration can be fully embodied by adopting the digital ink-jet decoration technology. Most of the natural stones, especially the natural marble and granite stones, need to be subjected to surface polishing treatment when in use, so that the flatness and surface smoothness of the stone surface can be enhanced, and the decoration and service performance of the stone can be improved. Therefore, in order to be closer to the texture and the decorative use effect of the natural stone, the digital ink-jet ceramic tile imitating the natural stone is sprayed with transparent glaze or protective glaze to cover after the ink-jet decoration process, and then surface polishing is carried out after sintering, so that the finally exhibited decorative effect is consistent with or close to that of the natural stone.

Although the existing ceramic tile process technology imitating natural stone can well imitate the vivid decoration effect of stone, especially novel rock plate products, in the production process, because the surface needs to be covered with a layer of transparent glaze or protective glaze, the problems that the glaze surface is lack of glaze and the glaze surface is uneven, so that the corrugation is obvious, polishing is needed, the excellent rate of finished products is low and the like are often caused due to the difference in physical properties among glaze materials, processes and ink.

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

Disclosure of Invention

In view of the defects of the prior art, the invention aims to provide an ultra-flat glaze for ceramic tiles, the ceramic tiles and a manufacturing method thereof, and aims to solve the problems that the glaze layer on the decorative ink of the ceramic tiles in the prior art has glaze shortage and corrugation, and the finished product rate of the ceramic tiles is low.

In order to solve the technical problems, the invention provides the following technical scheme: an ultra-flat glaze for ceramic tiles, wherein the ultra-flat glaze comprises the following components in percentage by mass:

20 to 40 percent of organic solvent;

40 to 70 percent of inorganic ceramic powder;

8 to 25 percent of macromolecular organic dispersant.

Further, the raw materials of the inorganic ceramic powder comprise, by weight:

1-3 parts of zinc oxide; 8-12 parts of barium carbonate; 30-50 parts of feldspar; 6-15 parts of calcined talc; 6-15 parts of a fused block particle; 6-15 parts of kaolin; 6-8 parts of calcined kaolin; 6-10 parts of calcium carbonate.

Further, the inorganic ceramic powder comprises the following raw materials in parts by weight:

2 parts of zinc oxide; 12 parts of barium carbonate; 42 parts of feldspar; 10 parts of calcined talc; 10 parts of a fused block particle; 8 parts of kaolin; 8 parts of calcined kaolin; 8 parts of calcium carbonate.

Further, the chemical composition of the inorganic ceramic powder comprises, by mass:

SiO₂ 45％～65％；Al₂O₃ 10％～20％；Fe₂O₃ 0～0.5％；CaO 4％～10％；MgO3％～10％；K₂O 0～2％；Na₂O 4％～8％；ZnO 1％～3％；BaO 8％～15％。

further, the chemical composition of the inorganic ceramic powder specifically comprises, by mass:

SiO₂ 55.47％；Al₂O₃ 16.48％；Fe₂O₃ 0.23％；CaO 6.37％；MgO 3.90％；K₂O 0.47％；Na₂O 4.69％；ZnO 2.17％；BaO 10.22％。

further, the viscosity of the organic solvent at 40 ℃ is 2-8 mPa & S;

the organic solvent comprises isopropyl laurate, isooctyl laurate, isopropyl myristate, isooctyl palmitate, isopropyl palmitate, dipropylene glycol methyl ether acetate, tripropylene glycol methyl ether, tripropylene glycol monobutyl ether, isomeric tridecanol polyoxyethylene ether or white oil;

the high molecular organic dispersant comprises polyester fatty acid amide;

the solid content of the super flat glaze is 65-75 percent; the glazing amount of the ultra-flat glaze is 260-420 g/m²(ii) a The fluidity of the ultra-flat glaze is 30-40 seconds; the fineness of the glaze slip of the ultra-flat glaze is 0.3-0.5% of the screen residue of a 325-mesh sieve.

In order to solve the above technical problems, the present invention provides another technical solution as follows: a method of making a ceramic tile comprising:

pressing, molding and drying the inorganic ceramic powder to obtain a plate-shaped ceramic tile blank;

applying a ground coat or a cover coat on the plate-shaped ceramic tile blank body through a spraying or showering process and drying to obtain a ground coat layer or a cover coat layer;

digitally printing decorative patterns on the ground glaze layer or the surface glaze layer by an ink jet printer to obtain a decorative pattern layer;

applying the ultra-flat glaze on the decorative pattern layer through a bell jar glaze spraying device to obtain an ultra-flat glaze layer;

and putting the ceramic tiles into a kiln for sintering to obtain the ceramic tiles.

Further, the solid content in the super flat glaze is 71%;

the glazing amount of the ultra-flat glaze is 360g/m²；

The fluidity of the ultra-flat glaze is 36 seconds;

the fineness of the glaze slip of the ultra-flat glaze is 0.32 percent of the screen residue of a 325-mesh sieve.

In order to solve the above technical problems, the present invention provides another technical solution as follows: ceramic tile, wherein the ceramic tile is manufactured by the method for manufacturing ceramic tile as described above.

Further, the ceramic tile comprises from bottom to top: a ceramic brick body layer, a ground glaze layer or a surface glaze layer, a decorative pattern layer and an ultra-flat glaze layer.

Has the advantages that: the invention provides an ultra-flat glaze for ceramic tiles, the ceramic tiles and a manufacturing method thereof, wherein the ultra-flat glaze comprises the following components in percentage by mass: 20 to 40 percent of organic solvent; 40 to 70 percent of inorganic ceramic powder; 8 to 25 percent of macromolecular organic dispersant. It can be understood that the inorganic ceramic powder is dispersed by the organic solvent, and the organic solvent replaces the aqueous medium in the traditional glaze slip, so that the inorganic ceramic powder can perfectly cover the existing oily decorative ink, and the glaze shortage on the decorative ink is effectively avoided; meanwhile, the polymer organic dispersing agent and the organic solvent are added into the super-flat glaze, so that secondary agglomeration and flocculation of superfine powder particles can be prevented, the viscosity of the glaze slip is greatly reduced, the fluidity of the glaze slip is improved, and inorganic ceramic powder with high solid content can be uniformly dispersed in the organic solvent, so that uniformly dispersed glaze is formed, a compact and fine glaze layer is formed on the decorative ink, the super-flat glaze layer does not need a polishing process, and can be distributed flatly, ripples are effectively avoided, and the goodness of a ceramic tile finished product is improved.

Drawings

FIG. 1 is a schematic flow chart of a method of making ceramic tiles provided in the present invention;

FIG. 2 is a perspective exploded view of a ceramic tile provided in the present invention;

description of reference numerals:

10. ceramic tiles; 11. a green ceramic body layer; 12. a ground coat layer; 13. a decorative pattern layer; 14. and (4) an ultra-flat glaze layer.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention clearer and clearer, the present invention is further described in detail below with reference to the accompanying drawings and examples. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

The surface decoration technology of building ceramic tiles is very abundant today, and besides the basic easy-to-clean performance of the decorative glaze on ceramic blanks, various patterns and colors on the surface of the glaze are often required to be decorated to improve the decoration performance of the ceramic tiles. In recent years, with the application and popularization of digital ink-jet technology, ink-jet decoration technology has become the main decoration method for ceramic tile pattern colors. The natural stone material has natural and fine decorative texture, rich color and distinct gradation. The decorative pattern of the digital ink-jet ceramic tile mainly simulates the texture of natural stone, and the fidelity or simulation degree of the ceramic tile decoration can be fully embodied by adopting the digital ink-jet decoration technology.

Most of the natural stones, especially the natural marble and granite stones, need to be subjected to surface polishing treatment when in use, so that the flatness and surface smoothness of the stone surface can be enhanced, and the decoration and service performance of the stone can be improved. Therefore, in order to be closer to the texture and the decorative use effect of the natural stone, the digital ink-jet ceramic tile imitating the natural stone is sprayed with transparent glaze or protective glaze to cover after the ink-jet decoration process, and then surface polishing is carried out after sintering, so that the finally exhibited decorative effect is consistent with or close to that of the natural stone.

Although the existing ceramic tile process technology imitating natural stone can well imitate the vivid decoration effect of stone, especially novel rock plate products, the following various problems often occur due to the difference in physical properties among glaze materials, processes and inks because the surface is covered with a layer of transparent glaze or protective glaze in the production process:

1. the glaze surface has glaze shortage; the decoration ink used by all the existing ceramic tile digital ink-jet is an organic solvent of hydrocarbon or ester, and solid ceramic inorganic pigment is mixed and dispersed, belonging to oily substances; the existing ceramic glaze takes water as a medium, and ceramic inorganic powder raw materials are mixed and dispersed, belonging to water-based substances; thus, the ink amount of the part with less pattern decoration is less, the glaze lack display is not obvious, and the glaze lack display is easy to occur in the pattern decoration area with larger ink amount;

2. the glaze surface has ripples; in the prior art, in order to solve the problem that the printing ink of the decorative pattern and the glaze slip are not mutually dissolved to generate the phenomenon of glaze shortage, the performance of the glaze slip can be modified. The glaze slip is added with a certain amount of the ink repellent, so that the glaze slip has the performance of water-based glaze slip and the performance of compatible jet printing ink. Or spraying a layer of ultrathin glaze slip after ink-jet decoration or printing a layer of isolation glaze slip by using a rubber roller, and the aim is to enable the transparent protective glaze to cover the pattern layer of the ink-jet decoration. However, the modification is still limited, and no matter the glaze spraying, glaze pouring, printing and other processes are adopted, although the glaze slip can cover the glaze layer, the phenomenon of uneven thickness of the glaze layer can occur in decorative areas with large ink amount and less ink amount, so that the illuminated lower surface is not smooth enough and shows more obvious ripples. Even if the surface is polished, the surface can not be completely leveled like the mirror flatness, the deepening of polishing has the risk of polishing the decorative patterns excessively, the control difficulty is increased, the normal polishing or the polishing is not smooth enough, the corrugation phenomenon exists, and the decorative effect is influenced.

3. The product has low quality rate. The water content of the green body is higher, and the green body is easy to damage and crack in the process of glaze line transportation, drying and sintering, especially for large-size and thin rock plate ceramic tiles; and the surface can not obtain the flatness as a mirror completely even if being polished, so that the risk of throwing off the decorative patterns due to excessive polishing exists in deepening the polishing, and the production goodness is influenced.

In conclusion, the invention provides the ultra-flat glaze for the ceramic tile, the ceramic tile and the manufacturing method thereof based on the problems that the glaze layer on the decorative ink of the ceramic tile in the prior art has the defects of glaze shortage and corrugation and the excellent product rate of the ceramic tile finished product is low, the inorganic ceramic powder is dispersed by the organic solvent, the organic solvent replaces the water medium in the traditional glaze slip, and then the inorganic ceramic powder can perfectly cover the prior oily decorative ink, so that the glaze shortage on the decorative ink is effectively avoided; meanwhile, by adding a high-molecular organic dispersant and an organic solvent into the super-flat glaze, secondary agglomeration and flocculation of ultrafine powder particles can be prevented, the viscosity of the glaze slip is greatly reduced, the fluidity of the glaze slip is improved, inorganic ceramic powder with high solid content can be uniformly dispersed in the organic solvent, so that uniformly dispersed glaze is formed, a compact and fine glaze layer is formed on the decorative ink, the super-flat glaze layer does not need a polishing process, and can be uniformly distributed, so that the occurrence of ripples is effectively avoided, and the goodness of a ceramic tile finished product is improved.

The invention provides an ultra-flat glaze for ceramic tiles, wherein the ultra-flat glaze comprises the following components in percentage by mass:

20 to 40 percent of organic solvent;

40 to 70 percent of inorganic ceramic powder;

8 to 25 percent of macromolecular organic dispersant.

It should be noted that the inorganic ceramic powder in the present invention is an inorganic ceramic powder in the prior art, for example, a transparent glaze formula commonly used for rock plate products that need to be polished at a later stage is an inorganic ceramic powder, but is not limited to the ceramic powder, and different inorganic ceramic powder formulas do not affect the effect of the ultra-flat glaze of the present invention. It can be understood that the inorganic ceramic powder is dispersed by the organic solvent, and the organic solvent replaces the aqueous medium in the traditional glaze slip, so that the inorganic ceramic powder can perfectly cover the existing oily decorative ink, and the glaze shortage on the decorative ink is effectively avoided; meanwhile, the polymer organic dispersing agent and the organic solvent are added into the super-flat glaze, so that secondary agglomeration and flocculation of superfine powder particles can be prevented, the viscosity of the glaze slip is greatly reduced, the fluidity of the glaze slip is improved, and inorganic ceramic powder with high solid content can be uniformly dispersed in the organic solvent, so that uniformly dispersed glaze is formed, a compact and fine glaze layer is formed on the decorative ink, the super-flat glaze layer does not need a polishing process, and can be distributed flatly, ripples are effectively avoided, and the goodness of a ceramic tile finished product is improved.

Further, the raw materials of the inorganic ceramic powder comprise, by weight:

1-3 parts of zinc oxide; 8-12 parts of barium carbonate; 30-50 parts of feldspar; 6-15 parts of calcined talc; 6-15 parts of a fused block particle; 6-15 parts of kaolin; 6-8 parts of calcined kaolin; 6-10 parts of calcium carbonate.

Further, the inorganic ceramic powder comprises the following raw materials in parts by weight:

2 parts of zinc oxide; 12 parts of barium carbonate; 42 parts of feldspar; 10 parts of calcined talc; 10 parts of a fused block particle; 8 parts of kaolin; 8 parts of calcined kaolin; 8 parts of calcium carbonate.

Further, the chemical composition of the inorganic ceramic powder comprises, by mass:

SiO₂ 45％～65％；Al₂O₃ 10％～20％；Fe₂O₃ 0～0.5％；CaO 4％～10％；MgO3％～10％；K₂O 0～2％；Na₂O 4％～8％；ZnO 1％～3％；BaO 8％～15％。

further, the chemical composition of the inorganic ceramic powder specifically comprises, by mass:

SiO₂ 55.47％；Al₂O₃ 16.48％；Fe₂O₃ 0.23％；CaO 6.37％；MgO 3.90％；K₂O 0.47％；Na₂O 4.69％；ZnO 2.17％；BaO 10.22％。

further, the viscosity of the organic solvent at 40 ℃ is 2-8 mPa & S;

the organic solvent comprises isopropyl laurate, isooctyl laurate, isopropyl myristate, isooctyl palmitate, isopropyl palmitate, dipropylene glycol methyl ether acetate, tripropylene glycol methyl ether, tripropylene glycol monobutyl ether, isomeric tridecanol polyoxyethylene ether or white oil;

the high molecular organic dispersant comprises polyester fatty acid amide;

the solid content of the super flat glaze is 65-75 percent; the glazing amount of the ultra-flat glaze is 260-420 g/m²(ii) a The fluidity of the ultra-flat glaze is 30-40 seconds; the fineness of the glaze slip of the ultra-flat glaze is 0.3-0.5% of the screen residue of a 325-mesh sieve.

The solvent of the super-flat glaze is set to be one or more organic solvents of alkanes, esters and ethers, the viscosity of the organic solvent is controlled, the inorganic ceramic powder can be uniformly dispersed to form uniformly dispersed glaze slip, the organic solvent replaces a water medium in the traditional glaze slip, the water medium can be perfectly covered on the existing oily decorative ink, and the glaze shortage on the decorative ink is effectively avoided; meanwhile, the polymer organic dispersing agent and the organic solvent are added into the super flat glaze, so that secondary agglomeration and flocculation of superfine powder particles can be prevented, the viscosity of the glaze slip is greatly reduced, the fluidity of the glaze slip is improved, and inorganic ceramic powder with higher solid content can be uniformly dispersed in the organic solvent, so that uniformly dispersed glaze is formed, a compact and fine glaze layer is formed on the decorative ink, the super flat glaze layer does not need a polishing process and can be distributed smoothly, the occurrence of ripples is effectively avoided, polishing processing is not needed, and the goodness of a finished ceramic tile product is effectively improved.

Referring to fig. 1, the present invention also provides a method for manufacturing a ceramic tile, comprising:

s11, pressing, molding and drying the inorganic ceramic powder to obtain a plate-shaped ceramic tile blank;

s12, applying a ground coat or a cover coat on the plate-shaped ceramic tile blank body through a spraying or sprinkling process and drying to obtain a ground coat or a cover coat;

step S13, digitally printing decorative patterns on the ground glaze layer or the surface glaze layer through an ink jet printer to obtain a decorative pattern layer;

step S14, applying the super-flat glaze on the decorative pattern layer through a bell jar glaze spraying device to obtain a super-flat glaze layer;

and step S15, obtaining the ceramic tile after the ceramic tile is put into a kiln and fired.

It can be understood that the method for manufacturing the ceramic tile provided by the invention can be used for uniformly covering the decorative ink by applying the super-flat glaze provided by the embodiment of the invention on the decorative pattern layer, so that the glaze shortage on the decorative ink is effectively avoided; moreover, the decorative printing ink can be coated with a compact and fine glaze layer, so that the super-flat glaze layer does not need a polishing process and can be distributed flatly, the occurrence of ripples is effectively avoided, and the goodness rate of a ceramic tile finished product is improved.

Further, the solid content in the super flat glaze is 71%;

the glazing amount of the ultra-flat glaze is 360g/m²；

The fluidity of the ultra-flat glaze is 36 seconds;

the fineness of the glaze slip of the ultra-flat glaze is 0.32 percent of the screen residue of a 325-mesh sieve.

The invention also provides a ceramic tile, wherein the ceramic tile is manufactured by the manufacturing method of the ceramic tile. The ceramic tile provided by the invention can be uniformly covered on the decorative printing ink by applying the super-flat glaze provided by the embodiment of the invention on the decorative pattern layer, so that the glaze shortage on the decorative printing ink is effectively avoided; moreover, the decorative printing ink can be coated with a compact and fine glaze layer, so that the super-flat glaze layer does not need a polishing process and can be distributed flatly, the occurrence of ripples is effectively avoided, and the goodness rate of a ceramic tile finished product is improved.

Referring to fig. 2, further, the ceramic tile 10 includes, from bottom to top: a ceramic tile body layer 11, a ground glaze layer 12 or a surface glaze layer, a decorative pattern layer 13 and an ultra-flat glaze layer 14.

The present invention will be described in further detail with reference to specific examples.

The first embodiment is as follows:

the embodiment provides an ultra-flat glaze for ceramic tiles, wherein the ultra-flat glaze comprises the following components in percentage by mass:

20 to 40 percent of organic solvent;

40 to 70 percent of inorganic ceramic powder;

8 to 25 percent of macromolecular organic dispersant.

The inorganic ceramic powder comprises the following raw materials in percentage by weight:

1-3 parts of zinc oxide; 8-12 parts of barium carbonate; 30-50 parts of feldspar; 6-15 parts of calcined talc; 6-15 parts of a fused block particle; 6-15 parts of kaolin; 6-8 parts of calcined kaolin; 6-10 parts of calcium carbonate.

The viscosity of the organic solvent at 40 ℃ is 2-8 mPa & S;

the organic solvent comprises isopropyl laurate, isooctyl laurate, isopropyl myristate, isooctyl palmitate, isopropyl palmitate, dipropylene glycol methyl ether acetate, tripropylene glycol methyl ether, tripropylene glycol monobutyl ether, isomeric tridecanol polyoxyethylene ether or white oil;

the high molecular organic dispersant comprises polyester fatty acid amide;

the solid content of the super flat glaze is 65-75 percent; the glazing amount of the ultra-flat glaze is 260-420 g/m²(ii) a The fluidity of the ultra-flat glaze is 30-40 seconds; the fineness of the glaze slip of the ultra-flat glaze is 0.3-0.5% of the screen residue of a 325-mesh sieve.

It can be understood that the inorganic ceramic powder is dispersed by the organic solvent, and the organic solvent replaces the aqueous medium in the traditional glaze slip, so that the inorganic ceramic powder can perfectly cover the existing oily decorative ink, and the glaze shortage on the decorative ink is effectively avoided; meanwhile, the polymer organic dispersing agent and the organic solvent are added into the super-flat glaze, so that secondary agglomeration and flocculation of superfine powder particles can be prevented, the viscosity of the glaze slip is greatly reduced, the fluidity of the glaze slip is improved, and inorganic ceramic powder with high solid content can be uniformly dispersed in the organic solvent, so that uniformly dispersed glaze is formed, a compact and fine glaze layer is formed on the decorative ink, the super-flat glaze layer does not need a polishing process, and can be distributed flatly, ripples are effectively avoided, and the goodness of a ceramic tile finished product is improved.

Example two:

the present embodiment provides an ultra-flat glaze for ceramic tiles, which is different from the ultra-flat glaze for ceramic tiles provided in the first embodiment above in that:

the inorganic ceramic powder comprises the following raw materials in parts by weight:

2 parts of zinc oxide; 12 parts of barium carbonate; 42 parts of feldspar; 10 parts of calcined talc; 10 parts of a fused block particle; 8 parts of kaolin; 8 parts of calcined kaolin; 8 parts of calcium carbonate.

Example three:

the present embodiment provides an ultra-flat glaze for ceramic tiles, which is different from the ultra-flat glaze for ceramic tiles provided in the first embodiment above in that:

the inorganic ceramic powder comprises the following chemical components in percentage by mass:

SiO₂ 45％～65％；Al₂O₃ 10％～20％；Fe₂O₃ 0～0.5％；CaO 4％～10％；MgO3％～10％；K₂O 0～2％；Na₂O 4％～8％；ZnO 1％～3％；BaO 8％～15％。

example four:

the present embodiment provides an ultra-flat glaze for ceramic tiles, which is different from the ultra-flat glaze for ceramic tiles provided in the first embodiment above in that:

the inorganic ceramic powder comprises the following chemical components in percentage by mass:

SiO₂ 55.47％；Al₂O₃ 16.48％；Fe₂O₃ 0.23％；CaO 6.37％；MgO 3.90％；K₂O 0.47％；Na₂O 4.69％；ZnO 2.17％；BaO 10.22％。

example five:

the present embodiment provides an ultra-flat glaze for ceramic tiles, which is different from the ultra-flat glaze for ceramic tiles provided in the first embodiment above in that:

the solid content of the super flat glaze is 71 percent;

the glazing amount of the ultra-flat glaze is specifically 360g/m²；

The fluidity of the ultra-flat glaze is specifically 36 seconds;

the glaze slurry fineness of the ultra-flat glaze is 0.32 percent of the screen residue of a 325-mesh sieve.

Example six:

referring to fig. 1, the present embodiment provides a method for manufacturing a ceramic tile, which includes:

s11, pressing, molding and drying the inorganic ceramic powder to obtain a plate-shaped ceramic tile blank;

s12, applying a ground coat or a cover coat on the plate-shaped ceramic tile blank body through a spraying or sprinkling process and drying to obtain a ground coat or a cover coat;

step S13, digitally printing decorative patterns on the ground glaze layer or the surface glaze layer through an ink jet printer to obtain a decorative pattern layer;

step S14, applying the super-flat glaze on the decorative pattern layer through a bell jar glaze spraying device to obtain a super-flat glaze layer;

and step S15, obtaining the ceramic tile after the ceramic tile is put into a kiln and fired.

It can be understood that the method for manufacturing the ceramic tile provided by the invention can be used for uniformly covering the decorative ink by applying the super-flat glaze provided by the embodiment of the invention on the decorative pattern layer, so that the glaze shortage on the decorative ink is effectively avoided; moreover, the decorative printing ink can be coated with a compact and fine glaze layer, so that the super-flat glaze layer does not need a polishing process and can be distributed flatly, the occurrence of ripples is effectively avoided, and the goodness rate of a ceramic tile finished product is improved.

Wherein the ultra-flat glaze in the step S14 comprises the following components in percentage by mass:

20 to 40 percent of organic solvent;

40 to 70 percent of inorganic ceramic powder;

8 to 25 percent of macromolecular organic dispersant.

It should be noted that the inorganic ceramic powder in the present invention is an inorganic ceramic powder in the prior art, for example, a transparent glaze formula commonly used for rock plate products that need to be polished at a later stage is an inorganic ceramic powder, but is not limited to the ceramic powder, and different inorganic ceramic powder formulas do not affect the effect of the ultra-flat glaze of the present invention. It can be understood that the inorganic ceramic powder is dispersed by the organic solvent, and the organic solvent replaces the aqueous medium in the traditional glaze slip, so that the inorganic ceramic powder can perfectly cover the existing oily decorative ink, and the glaze shortage on the decorative ink is effectively avoided; meanwhile, the polymer organic dispersing agent and the organic solvent are added into the super-flat glaze, so that secondary agglomeration and flocculation of superfine powder particles can be prevented, the viscosity of the glaze slip is greatly reduced, the fluidity of the glaze slip is improved, and inorganic ceramic powder with high solid content can be uniformly dispersed in the organic solvent, so that uniformly dispersed glaze is formed, a compact and fine glaze layer is formed on the decorative ink, the super-flat glaze layer does not need a polishing process, and can be distributed flatly, ripples are effectively avoided, and the goodness of a ceramic tile finished product is improved.

Further, the raw materials of the inorganic ceramic powder comprise, by weight:

1-3 parts of zinc oxide; 8-12 parts of barium carbonate; 30-50 parts of feldspar; 6-15 parts of calcined talc; 6-15 parts of a fused block particle; 6-15 parts of kaolin; 6-8 parts of calcined kaolin; 6-10 parts of calcium carbonate.

Further, the inorganic ceramic powder comprises the following raw materials in parts by weight:

2 parts of zinc oxide; 12 parts of barium carbonate; 42 parts of feldspar; 10 parts of calcined talc; 10 parts of a fused block particle; 8 parts of kaolin; 8 parts of calcined kaolin; 8 parts of calcium carbonate.

Further, the chemical composition of the inorganic ceramic powder comprises, by mass:

SiO₂ 45％～65％；Al₂O₃ 10％～20％；Fe₂O₃ 0～0.5％；CaO 4％～10％；MgO3％～10％；K₂O 0～2％；Na₂O 4％～8％；ZnO 1％～3％；BaO 8％～15％。

further, the chemical composition of the inorganic ceramic powder specifically comprises, by mass:

SiO₂ 55.47％；Al₂O₃ 16.48％；Fe₂O₃ 0.23％；CaO 6.37％；MgO 3.90％；K₂O 0.47％；Na₂O 4.69％；ZnO 2.17％；BaO 10.22％。

further, the viscosity of the organic solvent at 40 ℃ is 2-8 mPa & S;

the organic solvent comprises isopropyl laurate, isooctyl laurate, isopropyl myristate, isooctyl palmitate, isopropyl palmitate, dipropylene glycol methyl ether acetate, tripropylene glycol methyl ether, tripropylene glycol monobutyl ether, isomeric tridecanol polyoxyethylene ether or white oil;

the high molecular organic dispersant comprises polyester fatty acid amide;

the solid content of the super flat glaze is 65-75 percent; the glazing amount of the ultra-flat glaze is 260-420 g/m²(ii) a The fluidity of the ultra-flat glaze is 30-40 seconds; the fineness of the glaze slip of the ultra-flat glaze is 0.3-0.5% of the screen residue of a 325-mesh sieve.

Example seven:

the present embodiment provides a method for manufacturing a ceramic tile, which is different from the method for manufacturing a ceramic tile provided in the sixth embodiment in that:

the solid content in the super-flat glaze in the step S14 is 71%;

the glazing amount of the ultra-flat glaze is specifically 360g/m²；

The fluidity of the ultra-flat glaze is specifically 36 seconds;

the glaze slurry fineness of the ultra-flat glaze is 0.32 percent of the screen residue of a 325-mesh sieve.

Example eight:

the present embodiment provides a method for manufacturing a ceramic tile, which is different from the method for manufacturing a ceramic tile provided in the sixth embodiment in that:

the inorganic ceramic powder in the step S11 is an inorganic ceramic powder in the prior art, for example, a formula of a transparent glaze commonly used for rock plate products which need to be polished at a later stage is an inorganic ceramic powder, but is not limited to the ceramic powder, and different formulas of the inorganic ceramic powder do not affect the effect of the super-flat glaze of the present invention; and the ceramic tile compression molding mainly comprises high-pressure molding of a press die cavity or belt rolling type molding, the specification of the plate-shaped ceramic tile blank is generally more than 800 x 1600mm, or the ceramic tile product with the unilateral length exceeding 2400mm and the final thickness less than or equal to 9 mm. Meanwhile, the regular platy ceramic tile blank pressed in the step S11 is formed in a rolling type forming mode relative to a rock plate belt, the blank formed in the forming mode is in a non-regular rectangular shape, the edge part of the blank is uneven, and the blank is required to be cut and cut to form a regular rectangular shape after being formed.

Example nine:

referring to fig. 2, this embodiment provides a ceramic tile manufactured by the method for manufacturing the ceramic tile according to the above embodiment of the present invention.

Further, the ceramic 10 includes, in order from bottom to top: a ceramic tile body layer 11, a ground glaze layer 12 or a surface glaze layer, a decorative pattern layer 13 and an ultra-flat glaze layer 14.

It can be understood that the ceramic tile provided by the invention can be uniformly covered on the decorative ink by applying the super-flat glaze provided by the embodiment of the invention on the decorative pattern layer, so that the glaze shortage on the decorative ink is effectively avoided; moreover, the decorative printing ink can be coated with a compact and fine glaze layer, so that the super-flat glaze layer does not need a polishing process and can be distributed flatly, the occurrence of ripples is effectively avoided, and the goodness rate of a ceramic tile finished product is improved.

In summary, the present invention provides an ultra-flat glaze for ceramic tiles, a ceramic tile and a manufacturing method thereof, wherein the ultra-flat glaze comprises the following components by mass: 20 to 40 percent of organic solvent; 40 to 70 percent of inorganic ceramic powder; 8 to 25 percent of macromolecular organic dispersant. It can be understood that the inorganic ceramic powder is dispersed by the organic solvent, and the organic solvent replaces the aqueous medium in the traditional glaze slip, so that the inorganic ceramic powder can perfectly cover the existing oily decorative ink, and the glaze shortage on the decorative ink is effectively avoided; meanwhile, the polymer organic dispersing agent and the organic solvent are added into the super-flat glaze, so that secondary agglomeration and flocculation of superfine powder particles can be prevented, the viscosity of the glaze slip is greatly reduced, the fluidity of the glaze slip is improved, and inorganic ceramic powder with high solid content can be uniformly dispersed in the organic solvent, so that uniformly dispersed glaze is formed, a compact and fine glaze layer is formed on the decorative ink, the super-flat glaze layer does not need a polishing process, and can be distributed flatly, ripples are effectively avoided, and the goodness of a ceramic tile finished product is improved.

It is to be understood that the invention is not limited to the examples described above, but that modifications and variations may be effected thereto by those of ordinary skill in the art in light of the foregoing description, and that all such modifications and variations are intended to be within the scope of the invention as defined by the appended claims.