CN113173806A

CN113173806A - Production process of superfine dry particle ceramic large plate and product thereof

Info

Publication number: CN113173806A
Application number: CN202110495220.6A
Authority: CN
Inventors: 吴焱; 熊勋旺; 陈康; 陈健; 杨涛; 程津; 谢名辉; 李清莲
Original assignee: FENGCHENG DONGPENG CERAMIC CO LTD; Foshan Dongpeng Ceramic Co Ltd; Foshan Dongpeng Ceramic Development Co Ltd; Guangdong Dongpeng Holdings Co Ltd
Current assignee: FENGCHENG DONGPENG CERAMIC CO LTD; Foshan Dongpeng Ceramic Co Ltd; Foshan Dongpeng Ceramic Development Co Ltd; Guangdong Dongpeng Holdings Co Ltd
Priority date: 2021-05-07
Filing date: 2021-05-07
Publication date: 2021-07-27

Abstract

The invention discloses a production process of a superfine dry particle ceramic large plate and a product thereof, comprising the following steps: (1) brushing the blank and spraying water to wet the blank; (2) sequentially spraying surface glaze and ink-jet printing on the surface of the blank; (3) spraying dry particle glaze slurry on the surface of the blank obtained in the step (2) through a bell jar, wherein the dry particle glaze slurry comprises, by weight, 130 parts of a suspending agent in 110-45 parts of ultrafine dry particles and 4.5-11 parts of raw transparent glaze; the superfine dry particles comprise 19-21% of corundum powder; (4) and (5) sintering and brushing and polishing to obtain the superfine dry particle ceramic large plate. According to the invention, the glaze material is sprayed on the surface of the blank body, so that fine and smooth small particles with frosted texture are formed on the surface of the prepared ceramic large plate, the wear resistance and the skid resistance of the ceramic large plate are improved, and the problems of poor wear resistance and poor skid resistance effect of the conventional ceramic large plate are solved.

Description

Production process of superfine dry particle ceramic large plate and product thereof

Technical Field

The invention relates to the technical field of building ceramics, in particular to a production process of a superfine dry particle ceramic large plate and a product thereof.

Background

Along with the fire heat of the ceramic large plate, consumers pay more and more attention to the quality of the ceramic large plate, and the ceramic large plate can be attached to the ground and a background wall and can be cut into a cabinet plate, a table top and the like. According to different requirements of different consumers in application scenes on the quality of the ceramic large board, the ceramic large board products paved on the ground and the wall are rarely cut, and the consumers pay more attention to the wear resistance and the light transmission effect; for ceramic large plate products cut into cabinet plates and table tops, consumers have certain requirements on wear resistance and higher requirements on cutting performance.

At present, the existing ceramic large plate and rock plate are mainly prepared by full glaze polishing, the ceramic large plate and the rock plate prepared by full glaze polishing have the characteristics of smooth surface, high glossiness, good transparency and bright color, the glossiness can reach 60-70 degrees, and the pursuit of consumers for grandeury and light luxury decorative effect can be met.

However, the ceramic large plate prepared by the full-glaze-polishing method has poor wear resistance and anti-skid effect when being paved on the ground and the wall due to the very smooth surface, particularly, when the surface of the ceramic large plate is scratched or abraded carelessly, scratches and grinding marks are very obvious, the decorative effect of the ceramic large plate is influenced, and the anti-skid effect is worse after the surface of the ceramic large plate is stained with water. Meanwhile, when the ceramic large plate is cut and used as a table top, particularly as a kitchen table top, the ceramic large plate or the rock plate used as the kitchen table top has higher requirements on the wear resistance and the skid resistance because the surface of the ceramic large plate is more easily scratched due to the frequent use of a cutter in a kitchen.

Disclosure of Invention

Aiming at the problems brought forward by the background technology, the invention aims to provide a production process of a large superfine dry-particle ceramic plate, wherein fine and smooth small particles with frosted texture are formed on the surface of a finished product by spraying dry-particle glaze on the surface of the large ceramic plate, and the problems of poor wear resistance and poor anti-skid effect of the conventional large ceramic plate are solved.

The invention also aims to provide a ceramic large plate prepared by using the production process of the superfine dry particle ceramic large plate, wherein the surface of the ceramic large plate has fine and smooth small particles, so that the ceramic large plate has the characteristics of high wear resistance and good antiskid effect.

In order to achieve the purpose, the invention adopts the following technical scheme:

a production process of a superfine dry particle ceramic large plate comprises the following steps:

(1) brushing the blank and spraying water to wet the blank;

(2) sequentially spraying surface glaze and ink-jet printing on the surface of the blank;

(3) spraying dry particle glaze slurry on the surface of the blank obtained in the step (2) through a bell jar, wherein the raw materials of the dry particle glaze slurry comprise a suspending agent, ultrafine dry particles and raw transparent glaze;

(4) and (5) sintering and brushing and polishing to obtain the superfine dry particle ceramic large plate.

Further, in the step (3), the dry particle glaze slurry comprises, by weight, 130 parts of a suspending agent 110, 35-45 parts of ultrafine dry particles and 4.5-11 parts of a raw transparent glaze.

Further, in the step (3), the flow rate of the dry particle glaze slurry is 30-36s, and the glaze spraying amount is 28-32g/(350 × 350 mm).

Further, in the step (3), the raw materials of the superfine dry particles comprise, by mass, 25-30% of potassium feldspar, 20-25% of albite, 2-5% of calcined talc, 8-12% of dolomite, 5-8% of calcite, 7-12% of barium carbonate, 4-7% of strontium carbonate, 5-10% of nano corundum powder, 4-6% of washing kaolin, 5-8% of quartz and 3-6% of zinc oxide;

the chemical composition of the superfine dry particles in percentage by mass is as follows: 52-56% SiO₂、19-21％Al₂O₃、3-6％CaO、0.2-1％MgO、3-5％K₂O、2-4％Na₂O、8-10％BaO、3-5％SrO、2-4％ZnO。

Further, the particle fineness of the ultrafine dry particles is 120-350 meshes, and the particle fineness distribution is as follows according to the mass percentage: 120-200 meshes accounts for 36-40%, 200-250 meshes accounts for 32-36%, 250-325 meshes accounts for 20-24%, and less than or equal to 3.0% below 325 meshes.

Further, according to the mass parts, the raw transparent glaze comprises 30-40 parts of potassium feldspar, 10-13 parts of quartz, 8-12 parts of washing kaolin, 5-8 parts of wollastonite, 3-5 parts of zinc oxide, 15-20 parts of dolomite and 1-3 parts of calcined alumina;

the suspending agent comprises 96-98% of water, 0.5-1.0% of sodium carboxymethylcellulose, 0.2-0.5% of polyvinyl alcohol, 0.3-0.6% of hexanediol, 0.5-1.0% of glycerol by mass percentage.

Further, in the step (5), the brushing and polishing operation is specifically brushing and polishing by using 4-6 groups of wool pad abrasives of 180 meshes and 240 meshes, and the polishing depth is less than 0.01 mm.

Further, in the step (1), the blank body comprises 7.0-10.0% of ultra-white wollastonite, 3.0-6.0% of special-grade washed kaolin, 6.0-8.0% of peaceful and high white sand, 4.0-6.0% of Dongguo bentonite, 2.0-6.0% of Ducheng ball clay, 1.0-3.0% of ultra-white potassium sand, 3.0-5.0% of Yichun magnesia, 12.0-16.0% of construction high white ball clay, 3.0-5.0% of ultra-white washed kaolin, 10.0-14.0% of construction washed mud, 25.0-35.0% of Hubei water frosting and 0.5-1.0% of sodium tripolyphosphate by mass percentage;

the blank comprises the following raw materials in percentage by mass: 62-64% SiO₂、20.5-22.5％Al₂O₃、0-0.6％Fe₂O₃、0-0.05％TiO₂、2.5-3.5％CaO、1-1.5％MgO、1.5-2.5％K₂O、1.5-2.5％Na₂O, 6-7% loss on ignition.

Further, the overglaze comprises the following raw materials in percentage by mass: 15-20% of potassium feldspar, 15-20% of albite, 6-10% of water-washed kaolin, 20-25% of calcined kaolin, 10-15% of quartz, 5-8% of calcined alumina, 5-10% of talc and 2-4% of dolomite;

the flow rate of the overglaze is 32-36s, the specific gravity is 1.80-1.90g/ml, and the glazing amount is 55-65g/(350 multiplied by 350 mm).

The superfine dry particle ceramic large plate is prepared by the production process of the superfine dry particle ceramic large plate, the glossiness of the ceramic large plate is 5-10 degrees, and fine and smooth small particles are arranged on the surface of the ceramic large plate.

The invention has the beneficial effects that:

1. the invention leads the surface of the prepared superfine dry particle ceramic large plate to form fine granular feeling by spraying dry particle glaze on the surface of the blank body, because the glaze surface is formed by fusing one superfine dry particle together, the raised particles can be clearly observed under a magnifying glass of 30 times, because the surface of the ceramic large plate has fine particles which are rougher than the traditional glazed brick, the ceramic large plate is obstructed when being rubbed and is not easy to be worn and scratched, thereby improving the wear resistance of the ceramic large plate, and when the ceramic large plate is paved on the ground, the friction force between the brick surface and the sole can be improved due to the particles on the surface when people walk, thereby improving the anti-skid effect, and effectively solving the problems of poor wear resistance and poor anti-skid effect of the existing ceramic large plate.

2. The chemical components of the superfine dry particles of the invention mainly use bivalent barium, strontium and zinc as flux, the dosage of univalent potassium-sodium flux is reduced, and the higher the valence of metal is, the less alkali metal ions are precipitated, thereby improving the chemical corrosion resistance of the superfine dry particles. As the higher the Si/Al ratio is, the better the chemical corrosion resistance is, the Si/Al ratio in the chemical composition of the superfine dry particles reaches 2.6-2.8, the chemical corrosion resistance can be further improved, and the chemical corrosion resistance of the finished product reaches the double A standard.

3. Al in traditional glaze-polished or antique overglaze and protective glaze components₂O₃Mainly comes from calcined alumina, if the dosage of the alumina obtained by calcined alumina exceeds 18 percent, the permeation of the finished product is influenced, and in order to ensure the permeation of the superfine dry particles, Al in the formula of the superfine dry particles₂O₃Mainly comes from corundum powder with better penetration sense, the dosage of the corundum powder is 5-10%, so that Al in the superfine dry particles₂O₃The mass percentage of the ceramic material reaches 19-21%, so that the purpose of improving the surface wear resistance of the ceramic large panel is achieved while the transparent feeling is ensured.

Drawings

FIG. 1 is a surface view of a ceramic large plate according to an embodiment of the present invention, enlarged 30 times;

FIG. 2 is a graph of green body coefficient of expansion test data for one embodiment of the present invention;

FIG. 3 is a graph of overglaze coefficient of expansion test data in accordance with an embodiment of the present invention.

Detailed Description

The technical solution of the present invention is further described below with reference to the accompanying drawings and the detailed description.

(1) brushing the blank and spraying water to wet the blank;

(3) and (3) spraying dry particle glaze slip on the surface of the blank obtained in the step (2) through a bell jar, wherein the raw materials of the dry particle glaze slip comprise a suspending agent, ultrafine dry particles and raw transparent glaze.

Because the existing ceramic large board has poor wear resistance and anti-slip effect due to the fact that the glossiness of the ceramic large board reaches 60-70 degrees and the surface is very smooth in order to pursue the decorative effect of grandeur and light luxury, the invention forms fine granular feeling on the surface of a finished product by spraying dry glaze on the surface of a blank, and the raised particles can be clearly observed as shown in figure 1 because the glaze is formed by melting one ultrafine dry particle together and watching under a magnifying glass of 30 times. Because the ceramic large plate has tiny particles on the surface, the ceramic large plate is rougher than the traditional glazed brick, so that the ceramic large plate is obstructed when being rubbed, and is not easy to be worn and scratched, even if slight wear and scratch are generated, the attractiveness of the ceramic large plate is not influenced, and when the ceramic large plate is paved on the ground, the particles on the surface can improve the friction force between the brick surface and the sole when people walk, so that the antiskid effect is improved, and the problems of poor wear resistance and poor antiskid effect of the existing ceramic large plate can be effectively solved.

It is worth mentioning that, in the dry particle glaze slurry, the melting point of the suspending agent is the lowest, and the melting point of the ultrafine dry particles is the highest, the suspension property of the dry particle glaze slurry can be improved by adding the raw transparent glaze into the dry particle glaze slurry, and when the suspending agent is melted at 400 ℃ and becomes ineffective, the raw transparent glaze can provide enough supporting force for the ultrafine dry particles, so as to prevent the ultrafine dry particles from forming precipitates or being axially moved during firing to influence the granular feeling on the surface of the finished product, thereby influencing the wear resistance and the skid resistance of the finished product.

The dry particle glaze slurry adopts a wet glaze spraying process, ultrafine dry particles, a suspending agent and raw transparent glaze are uniformly mixed according to a certain proportion and then are sprayed on the surface of a blank body in a bell jar glaze spraying mode, the suspending agent is semi-oil, the raw transparent glaze is water-based, the suspending agent and the raw transparent glaze are not completely melted, and the raw transparent glaze is wrapped in the suspending agent along with the increase of the proportion of the raw transparent glaze, so that the viscosity of a mixed liquid is increased. The superfine dry particles are mixed with the suspending agent and the transparent glaze to form a sol-phobic system, and the superfine dry particles are easy to precipitate due to the large density of the superfine dry particles, so that the superfine dry particles can be wrapped in the raw transparent glaze, the suspending agent, the raw transparent glaze and the suspending agent to form repellent areas, and a relatively stable state is achieved.

Specifically, in the step (1), impurities and dust on the surface of the blank body discharged from the drying kiln are brushed away by a blank brushing machine, so that glaze spraying pinholes and blank bubbles after firing are prevented. Because the temperature of the green body discharged from the drying kiln is higher, the surface temperature of the green body is reduced by spraying water, so that the green body glaze is better combined, glaze spraying pinholes are avoided, the water spraying amount is generally controlled between 6 and 10g/(350 multiplied by 350mm), and the temperature of the green body can be properly adjusted according to the temperature of the green body. The overglaze in the step (2) has the main functions of whitening, color development assistance and brick shape adjustment, and can prevent a large amount of gas generated by blank oxidation from entering a dry particle layer. In the step (3), because the moisture content of the dry particle glaze slurry is larger, the drying temperature needs to be properly raised after spraying, the drying temperature is controlled to be 180 ℃ and 220 ℃, and the moisture content in the kiln is ensured to be below 0.8 percent. And (4) during polishing, the finished product is polished by using a brush flexibly, so that the surface of the finished product is fine and smooth in hand feeling and has high wear resistance, skid resistance and antifouling performance.

Specifically, in the firing process, after the ceramic large plate enters the kiln, the suspending agent begins to be slowly decomposed at about 500 ℃ and loses efficacy, and after the suspending agent loses efficacy, the risk that superfine dry particles are drawn away exists, so the temperature in a low box area at the head of the kiln needs to be properly reduced, the surface drawing of the kiln needs to be properly reduced, and the surface side drawing or the bottom drawing can be properly adjusted to ensure the stable pressure in the kiln. Due to the fluctuation of the kiln firing temperature, the influence on the hand feeling of the fired dry particle glaze is large, when the temperature is too high, the ultra-fine dry particles are too molten, the glaze is smooth, the granular feeling is not strong, and the wear resistance and the skid resistance are poor, when the temperature is too low, the ultra-fine dry particles are not molten enough, the surface of the ceramic large plate has rough hand feeling and is not fine and smooth enough, preferably, the firing temperature is 1200-1210 ℃, and the firing time is 120 minutes.

The dry grain glaze slip in the production process can be used for preparing ceramic large plates, and can also be used for preparing rock plates, so that the surfaces of the rock plates have granular feeling, and the wear resistance and the skid resistance of the rock plates are enhanced.

Further, in the step (3), the dry particle glaze slurry comprises, by weight, 130 parts of a suspending agent 110, 35-45 parts of ultrafine dry particles and 4.5-11 parts of raw transparent glaze.

4.5-11 parts of raw transparent glaze is added into the dry particle glaze slurry, so that the dry material mass percentage is 3% -6%, and the suspension property of the raw transparent glaze can be improved.

Specifically, if the amount of the suspending agent and the ultrafine dry particles exceeds or is less than the ratio, the thickness of a dry particle layer formed by the dry particle glaze slurry is affected, and a plurality of particle layers are too thick, so that the transparency of a finished product is poor and the hand feeling is rough; if some of the particle layers are too thin, the transparency of the finished product becomes strong, indicating too bright, strong gloss and no particle feel. The glossiness of the surface of a finished product can be improved due to excessive addition of the raw transparent glaze, so that the granular feeling of the finished product is poor, and the wear resistance and the anti-skid performance of the finished product are poor; if the addition amount of the raw transparent glaze is too small, the antifouling effect is affected and weakened.

Furthermore, in the step (3), the flow rate of the dry particle glaze slurry is 30-36s, and the glaze spraying amount is 28-32g/(350 multiplied by 350 mm).

The flow rate and the glaze pouring amount of the dry particle glaze slurry can directly influence the granular feeling and the fineness of the surface of a finished product, when the flow rate of the dry particle glaze slurry is too high or the glaze pouring amount is too large, the sprayed superfine dry particles can be increased, so that the dry particle layer of the dry particle layer is too thick, the transparency of the finished product is poor, the hand feeling is rough, and the appearance is influenced.

It is worth to be noted that, in the field of ceramics, the flow cup is used to detect the fluidity of slurry and glaze slip, and the operation method of the flow cup detection is as follows: before detecting the flow rate, the flow rate cup is required to be leveled, the flow rate cup is wiped clean by using wet cloth, the inner surface of the flow rate cup is slightly wet, the middle finger is used for pressing the outflow port of the flow rate cup, and the slurry is slowly poured into the flow rate cup until the surface of the slurry forms a convex liquid level. And (5) scraping the slurry until the slurry surface and the flow velocity cup mouth are on the same plane. Then, the stopwatch is pressed on while the middle finger is loosened, the stopwatch is observed to observe the outflow of the slurry, the stopwatch is pressed to stop in time when the slurry flows to the trickling position, and the time displayed on the stopwatch is read to be the flow speed.

It is worth to be noted that the traditional glaze polishing or antique overglaze and protective glaze all use potassium, sodium and zinc as flux, the chemical corrosion resistance is poor, and the double A standard can not be achieved, while the chemical components of the superfine dry particle of the invention mainly use bivalent barium, strontium and zinc as flux, the dosage of univalent potassium and sodium flux is reduced, and the higher the metal valence, the less the alkali metal ion precipitation amount, thereby improving the chemical corrosion resistance of the superfine dry particle. As the higher the silicon-aluminum ratio is, the better the chemical corrosion resistance is, the silicon-aluminum ratio in the superfine dry particle formula of the invention reaches 2.6-2.8, the chemical corrosion resistance can be further improved, and the chemical corrosion resistance of the finished product reaches the double A standard.

Al in traditional glaze-polished or antique overglaze and protective glaze components₂O₃Mainly comes from calcined alumina, if the dosage of the alumina exceeds 18 percent, the permeation of the finished product is influenced, and in order to ensure the permeation of ultrafine dry particles, Al in the formula₂O₃Mainly comes from the nano-grade corundum powder with better transparency, thereby achieving the purpose of improving the surface wear resistance of the ceramic large plate while ensuring the transparency.

It is worth to be noted that the ultrafine dry particles are particles with the fineness of 120-. Through adopting the granule of different mesh numbers, can make ceramic large panel surface form the sense of particle not of uniform size, make its vision more pleasing to the eye, dull polish feel effect, more when firing moreover, the tiny particle is filled in the close seam between the large granule, bonds the large granule after firing, and the combination of big and small granule can improve the density of dry grain glaze sintering to improve off-the-shelf antifouling nature.

Specifically, after the dry particles are crushed, round or oval dry particles are selected through the screen, and strip-shaped or block-shaped particles are avoided, because the strip-shaped or block-shaped particles easily cause screen blockage and the condition of scratching the bell jar in the process of glazing the bell jar.

Further, the raw transparent glaze comprises, by mass, 30-40 parts of potassium feldspar, 10-13 parts of quartz, 8-12 parts of washing kaolin, 5-8 parts of wollastonite, 3-5 parts of zinc oxide, 15-20 parts of dolomite and 1-3 parts of calcined alumina;

The raw transparent glaze has the main functions of improving the suspension property and the uniformity of glaze slip, improving the antifouling property and promoting the color development of ink, and simultaneously, the glossiness of the sintered superfine dry particles is adjusted by controlling the temperature of the raw transparent glaze, the adjusting period is shortened, and the production stability is greatly improved.

8-12 parts of washing kaolin is required to be added into the formula of the raw transparent glaze, so that the suspension property of the dry particle glaze slip can be improved, and the ultrafine dry particles can have enough supporting force after the suspending agent fails at 400-plus-500 ℃, thereby avoiding precipitation.

Further, in the step (5), the brushing and polishing operation is specifically brushing and polishing by using 4-6 groups of 180-mesh 240-mesh wool pad abrasives, and the polishing depth is less than 0.01 mm.

The conventional glazing and polishing mainly comprises an elastic module, the cutting amount of the elastic module is large, the elastic module is not suitable for shallow polishing, and the superfine dry particle ceramic large plate product is brushed and polished by using wool pad grinding materials, so that the surface glossiness of the plate product is 5-10 degrees, and the plate product has fine hand feeling and soft gloss. Moreover, because the brushing and polishing depth is shallow, the surface of the dry particle layer is almost free of open pores, so that the produced ceramic large plate can achieve an antifouling effect without waxing.

Further, in the step (1), the blank body comprises 7.0-10.0% of ultra-white wollastonite, 3.0-6.0% of special-grade washed kaolin, 6.0-8.0% of peaceful high white sand, 4.0-6.0% of Dongguo bentonite, 2.0-6.0% of Ducheng ball clay, 1.0-3.0% of ultra-white potassium sand, 3.0-5.0% of Yichun magnesia, 12.0-16.0% of construction high white ball clay, 3.0-5.0% of ultra-white washed kaolin, 10.0-14.0% of construction washed mud, 25.0-35.0% of Hubei water frosting and 0.5-1.0% of sodium tripolyphosphate by mass percentage;

the chemical composition of the raw materials of the green body is as follows according to the mass percentage: 62-64% SiO₂、20.5-22.5％Al₂O₃、0-0.6％Fe₂O₃、0-0.05％TiO₂、2.5-3.5％CaO、1-1.5％MgO、1.5-2.5％K₂O、1.5-2.5％Na₂O, 6-7% loss on ignition.

It is worth to say that the formula of the invention adopts a calcium-magnesium system, and the system has the main characteristics of small sintering shrinkage, small expansion coefficient, capability of controlling the sintering degree of a blank body, contribution to the generation of a blank glaze intermediate layer, capability of effectively solving the problems of cracking of a glaze layer and cutting and cracking of a large plate during processing, and particularly, the expansion coefficient of the blank body is (4.52-6.95) multiplied by 10^-6/K^-1The detection data are shown in FIG. 2 below.

The blank is formed by adopting a sago roller press, so that the crushing of blank powder caused by extrusion in the rolling process is avoided, the mud consumption in the blank raw material is increased, and the strength of the blank powder is stronger.

Specifically, the blank raw materials are subjected to ball milling, sieving to remove iron, powder spraying and granulation in sequence to obtain powder, wherein according to the mass percentage, the water content of the powder is 8.0-8.8%, the proportion of particles with the particle fineness of 40-60 meshes is 95-98%, and the volume weight of the powder is 0.92-0.95.

Because the sago roller press is formed by belt roller pressing, different from the traditional punch, the sago roller press has different requirements on the flowability of powder, the sago roller press requires better flowability of the powder, the strength of powder particles is good, and the powder particles can not be crushed by extrusion force, so that the moisture content of the powder is improved by 1-2% in the powder spraying and granulating stage relative to the traditional press, the moisture content of blank powder is controlled between 8.0-8.8%, and the blank is more favorable for forming; the particle fineness of the powder is controlled to be 40-60 meshes, the particle fineness is most favorable for rolling of particles and enhancing the flowability of the powder, and if the particles are too large, the particles roll slowly and the flowability of the powder is poor; if the particles are too small, the particles tend to be electrostatically adsorbed, which also results in poor flowability.

Preferably, the proportion of particles with the powder fineness of 40-60 meshes is 95-98%, the proportion of particles with the fineness of 20 meshes is less than or equal to 2.0%, and the proportion of particles with the fineness of more than 100 meshes is less than or equal to 3.0%, wherein the powder fineness is mainly 60 meshes, and the proportion of particles with the powder fineness of 60 meshes is 80-94%.

when the overglaze is applied, the flow rate of the overglaze is 32-36s, the specific gravity is 1.80-1.90g/ml, and the glazing amount is 55-65 g/(350X 350 mm).

It is worth to be noted that, because the blank body of the invention adopts a calcium-magnesium system, the expansion coefficient of the calcium-magnesium system is very small, and the capability of the overglaze for bearing pressure is larger than the capability for bearing tensile stress, the expansion coefficient of the overglaze is close to or slightly smaller than that of the blank body, so that the overglaze is matched with the blank body, and if the expansion coefficient of the overglaze is too large, the overglaze layer is easy to crack, thus affecting the later processing and cutting of the product. The formula of the overglaze adopts 20-25% of calcined kaolin to reduce the expansion coefficient of the overglaze, so that the overglaze is effectively combined with a blank of a calcium-magnesium system, the high-temperature viscosity of the overglaze can be increased, and gas generated by the blank is reduced from entering a dry particle layer formed by dry particle glaze slurry.

Preferably, the overglaze has a coefficient of expansion of (3.95-6.66). times.10^-6The measurement data are shown in FIG. 3 below.

The glossiness of the surface glaze after single glazing and scraping can affect the glossiness of the whole product, the frosted texture and the hand feeling of the surface, in order to control the glossiness of the surface of the ceramic large panel to be 5-10 degrees, the glossiness of the surface glaze after single glazing and scraping needs to be controlled to be 5-8 degrees, the glossiness of the surface glaze after single glazing and scraping can be controlled by controlling the temperature, the flow rate, the specific gravity and the glazing amount of the surface glaze, and preferably, the flow rate of the surface glaze is 32-36s, the specific gravity is 1.80-1.90g/ml, and the glazing amount is 55-65g/(350 multiplied by 350 mm).

The ceramic large plate is prepared by the production process of the ceramic large plate with the superfine dry particles, the glossiness of the ceramic large plate is 5-10 degrees, and fine and smooth small particles are arranged on the surface of the ceramic large plate.

The present invention will be further illustrated below by reference to examples and comparative examples.

Examples 1 to 7

(1) carrying out blank brushing and water spraying wetting treatment on the blank, wherein the water spraying amount is 8g/(350 multiplied by 350 mm);

(3) and (3) spraying dry granular glaze slurry on the surface of the blank body obtained in the step (2) through a bell jar at the flow rate of 30-36s and the glaze spraying amount of 28-32g/(350 multiplied by 350mm), drying the blank body after the spraying of the dry granular glaze slurry is finished, controlling the temperature to be 200 ℃, and controlling the weight percentage of the dried blank to be 0.8%.

The dry particle glaze slurry comprises, by weight, 130 parts of a suspending agent of 110-45 parts of ultrafine dry particles and 4.5-11 parts of raw transparent glaze, wherein the ultrafine dry particles comprise, by mass, 5-10% of nano-scale corundum powder, and the ultrafine dry particles comprise, by mass: 52-56％SiO₂、19-21％Al₂O₃、3-6％CaO、0.2-1％MgO、3-5％K₂O、2-4％Na₂O, 8-10% BaO, 3-5% SrO and 2-4% ZnO; the fineness distribution of the superfine dry particles is as follows: 120-200 meshes accounts for 36-40%, 200-250 meshes accounts for 32-36%, 250-325 meshes accounts for 20-24%, and less than or equal to 3.0% below 325 meshes.

(4) And (3) sintering, wherein the sintering temperature is 1210 ℃, the sintering time is 120 minutes, brushing and polishing are carried out, and the specific operation of brushing and polishing is to brush and polish 5 groups of wool pad abrasives of 200 meshes, wherein the polishing depth is less than 0.01mm, so that the superfine dry particle ceramic large plate is obtained.

In particular, the specific parameters of examples 1-7 are shown in Table 1 below:

table 1 specific parameters of example group a

Specifically, the ultrafine dry particle ceramic large plate is prepared by the parameters in the table above and the production process, and the wear resistance, skid resistance, acid resistance, alkali resistance and fineness of the obtained ultrafine dry particle ceramic large plate are measured by the method in the following table 2, and the detection results are shown in the following table 3.

TABLE 2 detection methods

Performance of	Detection method
		Wear resistance	Detect the weight worn by 12000 turns through a wear-resisting detector
Non-skid property	Coefficient of static friction (Wet process)
		Acid resistance	National Standard method
Alkali resistance	National Standard method
		Hand feeling and look	Touch feeling and visual observation

Table 3 results of performance testing of example group a

As can be seen from the performance test results in Table 3, the ceramic slabs prepared by the production process of the ultrafine dry particle ceramic slabs of examples 1 to 7 all had a frosted surface, and had a fine and smooth hand feeling, a soft light feeling, and a good transparency. Meanwhile, the wear-resistant rubber has high wear resistance, and the weight of the wear-resistant rubber is below 0.2 g when the wear-resistant rubber is detected by a wear-resistant detector at 12000 revolutions; the static friction coefficient of the surface of the ceramic large plate is detected by a wet method, the static friction coefficient is more than 1.0 and is far higher than that of a common glazed brick, so that the anti-skid performance of the ceramic large plate in the embodiment 1-7 is good; in addition, the acid resistance and the alkali resistance of the ceramic large plate can reach A level, which indicates that the chemical corrosion resistance of the ceramic large plate reaches the double A standard.

Comparative example 1

The production process of this comparative example was substantially the same as that of example 5 except that the raw materials of the dry grain glaze slurry of this comparative example included 130 parts of a suspending agent and 43 parts of ultrafine dry grains without containing a raw transparent glaze, an ultrafine dry grain ceramic panel was prepared according to the production process of example 5, and the abrasion resistance, slip resistance, acid resistance, alkali resistance and fineness of the obtained ultrafine dry grain ceramic panel were measured according to the method of table 2, and the results of the measurements are shown in table 5 below.

Comparative example 2

The production process of this comparative example was substantially the same as that of example 5 except that Al in the ultrafine dry particles in this comparative example was contained in₂O₃The components are mainly provided by calcined alumina, the raw materials of the components do not comprise nano-scale corundum powder, the superfine dry-particle ceramic large plate is prepared according to the production process of the embodiment 5, the wear resistance, the skid resistance, the acid resistance, the alkali resistance and the fineness of the obtained superfine dry-particle ceramic large plate are measured according to the method shown in the table 2, and the detection results are shown in the following table 5.

Comparative examples 3 to 6

The production process of this comparative example was substantially the same as that of example 5 except that the particle fineness distribution of the ultrafine dry particles in comparative examples 3 to 6 was different from that of example 5, and the particle fineness distribution of the ultrafine dry particles in comparative examples 3 to 6 was as shown in the following Table 4:

TABLE 4 particle fineness distribution of ultrafine dry particles in comparative examples 3 to 6

The ultra-fine dry particle ceramic panel obtained by the manufacturing process of example 5 was measured for wear resistance, slip resistance, acid resistance, alkali resistance and fineness according to the method shown in table 2, and the results are shown in table 5 below.

TABLE 5 results of testing the properties of comparative examples 1 to 7

As can be seen from the performance test of table 5, in comparative example 1, when the raw material of the dry-particle glaze slurry does not use the raw transparent glaze, the abrasion resistance and the anti-slip effect of the obtained ceramic large panel are reduced, and the surface of the ceramic large panel of comparative example 1 has a weak frosted feeling; in comparative example 2, calcined alumina was used instead of the nano-grade corundum powder, and although the wear resistance and the anti-slip effect of the obtained ceramic large plate were almost the same as those of example 5, the surface of the ceramic large plate had poor transparency, which affected the overall beauty; in comparative examples 3 and 4, the mesh number of part of the ultrafine dry particles is more than 120 meshes, the proportion of the particles with the mesh size of 120-325 meshes is reduced, the surface of the prepared ceramic large panel has very strong frosting sense, rough hand feeling and influence on beauty, and the hand feeling is more rough along with the increase of the particles with the mesh size of more than 120 meshes; in comparative examples 5 and 6, since the fineness of the ultra fine dry particles is small, the grain feeling of the surface of the prepared ceramic panel is weak, resulting in a decrease in abrasion resistance and slip resistance.

The technical principle of the present invention is described above in connection with specific embodiments. The description is made for the purpose of illustrating the principles of the invention and should not be construed in any way as limiting the scope of the invention. Based on the explanations herein, those skilled in the art will be able to conceive of other embodiments of the present invention without inventive effort, which would fall within the scope of the present invention.

Claims

1. The production process of the superfine dry particle ceramic large plate is characterized by comprising the following steps:

(1) brushing the blank and spraying water to wet the blank;

2. The process for producing an ultra-fine dry particle ceramic panel as claimed in claim 1, wherein in the step (3), the dry particle glaze slurry comprises 130 parts by weight of a suspending agent 110, 35-45 parts by weight of ultra-fine dry particles and 4.5-11 parts by weight of raw transparent glaze.

3. The process for producing ultra-fine dry particle ceramic panels as claimed in claim 1, wherein in the step (3), the flow rate of the dry particle glaze slurry is 30-36s, and the glaze spraying amount is 28-32g/(350 x 350 mm).

4. The process for producing ultra-fine dry-granulated ceramic large plates according to claim 1, wherein in the step (3), the raw materials of the ultra-fine dry granules comprise, by mass, 25 to 30% of potassium feldspar, 20 to 25% of albite, 2 to 5% of calcined talc, 8 to 12% of dolomite, 5 to 8% of calcite, 7 to 12% of barium carbonate, 4 to 7% of strontium carbonate, 5 to 10% of nano-corundum powder, 4 to 6% of water-washed kaolin, 5 to 8% of quartz, and 3 to 6% of zinc oxide;

5. The production process of the ceramic large plate with the ultrafine dry particles as claimed in claim 4, wherein the particle fineness of the ultrafine dry particles is 120-350 meshes, and the particle fineness distribution is as follows according to mass percent: 120-200 meshes accounts for 36-40%, 200-250 meshes accounts for 32-36%, 250-325 meshes accounts for 20-24%, and less than or equal to 3.0% below 325 meshes.

6. The process for producing ultra-fine dry particle ceramic large plates according to claim 1, wherein the raw transparent glaze comprises, by mass, 30-40 parts of potassium feldspar, 10-13 parts of quartz, 8-12 parts of water-washed kaolin, 5-8 parts of wollastonite, 3-5 parts of zinc oxide, 15-20 parts of dolomite, and 1-3 parts of calcined alumina;

7. The process for producing ultra-fine dry particle ceramic slabs as claimed in claim 1, wherein in the step (5), the brushing operation is performed by brushing 4-6 groups of 180-240 mesh wool pad abrasives, and the polishing depth is less than 0.01 mm.

8. The process for producing ultra-fine dry particle ceramic panels as claimed in claim 1, wherein in the step (1), the raw materials of the green body comprise 7.0-10.0% of ultra-white wollastonite, 3.0-6.0% of extra-grade washed kaolin, 6.0-8.0% of peaceful white sand, 4.0-6.0% of Dong's Ore bentonite, 2.0-6.0% of Ducheng ball clay, 1.0-3.0% of ultra-white potassium sand, 3.0-5.0% of Yichun magnesia, 12.0-16.0% of high white ball clay for construction industry, 3.0-5.0% of ultra-white washed kaolin, 10.0-14.0% of Hubei lake mud, 25.0-35.0% of North water frosting and 0.5-1.0% of sodium tripolyphosphate by mass percentage;

9. The process for producing the ultra-fine dry particle ceramic panel as claimed in claim 1, wherein the overglaze comprises the following raw materials by mass percent: 15-20% of potassium feldspar, 15-20% of albite, 6-10% of water-washed kaolin, 20-25% of calcined kaolin, 10-15% of quartz, 5-8% of calcined alumina, 5-10% of talc and 2-4% of dolomite;

10. An ultra-fine dry particle ceramic panel, which is prepared by the process for producing an ultra-fine dry particle ceramic panel according to any one of claims 1 to 9, and which has a gloss of 5 to 10 degrees and fine and smooth fine particles on the surface.