CN114516722A - Protective glaze suitable for being fired in low-temperature fast-firing kiln, ceramic tile and preparation method thereof - Google Patents
Protective glaze suitable for being fired in low-temperature fast-firing kiln, ceramic tile and preparation method thereof Download PDFInfo
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- CN114516722A CN114516722A CN202210227672.0A CN202210227672A CN114516722A CN 114516722 A CN114516722 A CN 114516722A CN 202210227672 A CN202210227672 A CN 202210227672A CN 114516722 A CN114516722 A CN 114516722A
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- 230000001681 protective effect Effects 0.000 title claims abstract description 107
- 238000010304 firing Methods 0.000 title claims abstract description 99
- 239000000919 ceramic Substances 0.000 title claims abstract description 35
- 238000002360 preparation method Methods 0.000 title abstract description 11
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims abstract description 28
- 238000000034 method Methods 0.000 claims abstract description 22
- 238000005507 spraying Methods 0.000 claims abstract description 15
- 239000002994 raw material Substances 0.000 claims abstract description 10
- 229910052593 corundum Inorganic materials 0.000 claims abstract description 4
- 229910001845 yogo sapphire Inorganic materials 0.000 claims abstract description 4
- 239000002002 slurry Substances 0.000 claims description 28
- 230000005484 gravity Effects 0.000 claims description 21
- 238000005498 polishing Methods 0.000 claims description 16
- 238000000498 ball milling Methods 0.000 claims description 15
- 239000005995 Aluminium silicate Substances 0.000 claims description 14
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 14
- 235000012211 aluminium silicate Nutrition 0.000 claims description 14
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 14
- 239000000203 mixture Substances 0.000 claims description 11
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 10
- 229910021532 Calcite Inorganic materials 0.000 claims description 8
- 239000010459 dolomite Substances 0.000 claims description 8
- 229910000514 dolomite Inorganic materials 0.000 claims description 8
- 229910052656 albite Inorganic materials 0.000 claims description 7
- BDAGIHXWWSANSR-NJFSPNSNSA-N hydroxyformaldehyde Chemical compound O[14CH]=O BDAGIHXWWSANSR-NJFSPNSNSA-N 0.000 claims description 7
- 229910000018 strontium carbonate Inorganic materials 0.000 claims description 7
- 239000000454 talc Substances 0.000 claims description 7
- 229910052623 talc Inorganic materials 0.000 claims description 7
- 239000011787 zinc oxide Substances 0.000 claims description 7
- DLHONNLASJQAHX-UHFFFAOYSA-N aluminum;potassium;oxygen(2-);silicon(4+) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[Al+3].[Si+4].[Si+4].[Si+4].[K+] DLHONNLASJQAHX-UHFFFAOYSA-N 0.000 claims description 6
- 229910052742 iron Inorganic materials 0.000 claims description 5
- 230000036571 hydration Effects 0.000 claims description 4
- 238000006703 hydration reaction Methods 0.000 claims description 4
- 230000005389 magnetism Effects 0.000 claims description 4
- 238000002156 mixing Methods 0.000 claims description 4
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 4
- 238000005303 weighing Methods 0.000 claims description 4
- 238000012216 screening Methods 0.000 claims description 3
- 239000011248 coating agent Substances 0.000 claims 1
- 238000000576 coating method Methods 0.000 claims 1
- 230000007547 defect Effects 0.000 abstract description 14
- 230000000694 effects Effects 0.000 abstract description 13
- 238000005245 sintering Methods 0.000 abstract description 12
- 230000000630 rising effect Effects 0.000 abstract description 7
- 238000004519 manufacturing process Methods 0.000 abstract description 5
- KKCBUQHMOMHUOY-UHFFFAOYSA-N Na2O Inorganic materials [O-2].[Na+].[Na+] KKCBUQHMOMHUOY-UHFFFAOYSA-N 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 84
- 230000000052 comparative effect Effects 0.000 description 23
- 239000011449 brick Substances 0.000 description 11
- 239000000463 material Substances 0.000 description 10
- 238000002844 melting Methods 0.000 description 7
- 230000008018 melting Effects 0.000 description 7
- 230000002829 reductive effect Effects 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 238000010521 absorption reaction Methods 0.000 description 3
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 2
- 230000004075 alteration Effects 0.000 description 2
- 238000000889 atomisation Methods 0.000 description 2
- 230000000903 blocking effect Effects 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000006467 substitution reaction Methods 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 241001270131 Agaricus moelleri Species 0.000 description 1
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 1
- 230000003373 anti-fouling effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000007865 diluting Methods 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
- 239000012895 dilution Substances 0.000 description 1
- 239000010433 feldspar Substances 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 230000002401 inhibitory effect Effects 0.000 description 1
- 238000002955 isolation Methods 0.000 description 1
- 230000000670 limiting effect Effects 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 229940072033 potash Drugs 0.000 description 1
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Substances [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 description 1
- 235000015320 potassium carbonate Nutrition 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 230000001502 supplementing effect Effects 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C8/00—Enamels; Glazes; Fusion seal compositions being frit compositions having non-frit additions
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/52—Multiple coating or impregnating multiple coating or impregnating with the same composition or with compositions only differing in the concentration of the constituents, is classified as single coating or impregnation
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
- C04B41/89—Coating or impregnation for obtaining at least two superposed coatings having different compositions
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Structural Engineering (AREA)
- Life Sciences & Earth Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Finishing Walls (AREA)
Abstract
The invention discloses a protective glaze suitable for being fired in a low-temperature fast-firing kiln, ceramic tiles and a preparation method thereof, wherein the protective glaze comprises the following raw materials in percentage by weight: SiO 22、Al2O3、CaO、MgO、K2O、Na2O and loss on ignition; the sintering temperature of the protective glaze in the low-temperature rapid sintering kiln is 1199-1230 ℃, and the sintering time is 50-55 min; the tension of the protective glaze effectively prevents the overglaze layer, the ink spraying layer and bubbles generated in the pressed blank body from breaking through the glaze layer; the ceramic tile fired by the low-temperature fast firing kiln, disclosed by the invention, has the advantages that the protective glaze is distributed above the ink jet layer between the overglaze and the glaze, the thickness is small, bubbles can be effectively prevented from rising, and the ceramic tile has the effect of protecting the ink jet layer and the glaze layer from generating air holes and recessed glaze defects; the preparation method of the protective glaze suitable for being fired in the low-temperature fast-firing kiln, which is provided by the invention, has simple process and can not cause the manufacturing cost of the product to be obviously increased。
Description
Technical Field
The invention relates to the technical field of ceramic glaze materials, in particular to protective glaze suitable for being fired in a low-temperature fast-firing kiln, a ceramic tile and a preparation method thereof.
Background
The surface defects of ceramic tiles are formed as follows: the green brick contains carbonate, closed air holes or open holes exist on the surface of the green brick, when the glaze is sprayed on the overglaze again, the closed air holes or the open holes on the surface of the overglaze are closed, the carbonate is decomposed and gasified to generate a large amount of gas and collect the gas into bubbles during firing, the gas in the closed air holes or the open holes can also form the bubbles after collecting a certain amount, the bubbles collect to increase the volume, so that a glaze layer is broken through, and the defects of pinholes and concave glaze are formed on the glaze surface.
In order to improve the energy-saving and environment-friendly performance of ceramic tile production, the ceramic tile kiln in the prior art is upgraded and modified, the maximum firing temperature of the kiln is limited, the process is optimized, the firing time is shortened, and the low-temperature fast firing process in the prior art is formed.
Because the low-temperature fast firing process has a narrow firing temperature range and short firing time, if the process for preventing the protective glaze from the glaze surface pinholes in the prior art is adopted, the protective glaze for preventing the pinholes in the prior art is sprayed and applied between the overglaze and the polished glaze, the viscosity of the protective glaze for preventing the pinholes in the prior art is too high, and the applied thickness is 0.3-0.5mm, so that the transparency of a product fired by the low-temperature fast firing process is poor, and the phenomenon of opacification is easy to occur, thereby causing batch unqualified products to appear on the product.
Disclosure of Invention
The invention aims to provide a protective glaze suitable for being fired in a low-temperature fast-firing kiln, which can effectively inhibit bubbles in a glaze layer from rising to form pinholes in a low-temperature fast-firing process and solve the technical problem that products in the low-temperature fast-firing process are easy to be unqualified in batches.
The second purpose of the invention is to provide a low-temperature fast-firing kiln-fired ceramic tile, which uses a protective glaze suitable for low-temperature fast-firing kiln firing, and the protective glaze is coated above the ink-jet layer, so that bubbles can be effectively prevented from rising.
The third purpose of the invention is to provide a preparation method of the protective glaze suitable for being fired in the low-temperature fast-firing kiln, which is simple in process.
In order to achieve the purpose, the invention adopts the following technical scheme:
a protective glaze suitable for being fired in a low-temperature fast-firing kiln comprises the following raw materials in percentage by weight: SiO 22 45-49wt％、Al2O3 23-26wt％、CaO 2.5-4wt％、MgO 4-6wt％、K2O 0.5-1.5wt％、Na2O3-4 wt% and loss on ignition 14-18 wt%;
the thickness of the protective glaze is 0.05-0.06mm, the sintering temperature of the protective glaze in the low-temperature fast-sintering kiln is 1185-1235 ℃, and the sintering time is 50-55 min.
Specifically, the raw materials of the protective glaze comprise, by weight, 5-10% of potash feldspar, 30-40% of albite, 1-3% of calcined kaolin, 2-3% of zinc oxide, 4-8% of water-washed kaolin, 8-12% of calcined talc, 4-6% of strontium carbonate, 4-6% of calcite, 10-15% of alumina and 5-8% of dolomite.
Further, the initial melting temperature of the protective glaze is 1210-1220 ℃.
Further, the invention also provides a ceramic tile fired by the low-temperature fast-firing kiln, which sequentially comprises a green brick, a cover glaze layer, an ink spraying layer, a protective glaze layer and a glaze polishing layer from bottom to top, wherein the protective glaze layer is the protective glaze suitable for firing the ceramic tile by the low-temperature fast-firing kiln; the thickness of the protective glaze layer is greater than that of the ink spraying layer, and the thickness of the protective glaze layer is 0.01-0.02 time of that of the overglaze layer;
the glaze used for the overglaze layer is a conventional glaze with the aluminum oxide content of 13-15 wt% respectively;
the glaze used for the glaze polishing layer is a conventional glaze with the alumina content of 23-26 wt%;
when the average gray scale of the ink-jet layer is less than or equal to 50 ℃, the surface temperature of the firing area of the low-temperature fast firing kiln is 1200 +/-5 ℃, and the bottom temperature of the firing area of the low-temperature fast firing kiln is 1230 +/-5 ℃.
Preferably, when the average gray scale of the ink jet layer is greater than 50, the surface temperature of the firing area of the low-temperature fast firing kiln is 1190 +/-5 ℃, and the bottom temperature of the firing area of the low-temperature fast firing kiln is 1227 +/-5 ℃.
Preferably, when the average gray scale of the ink-jet layer is less than or equal to 50, the specific gravity of the protective glaze is 1.38 +/-0.02 g/ml, and the glazing amount of the corresponding protective glaze applied is 45-50 g/square meter; when the average gray scale of the ink-jet layer is more than 50, the specific gravity of the applied protection glaze is 1.33 +/-0.02 g/ml, and the corresponding glazing amount of the protection glaze is 32-35 g/square meter.
Further, the invention also provides a preparation method of the protective glaze suitable for being fired in the low-temperature fast-firing kiln, which comprises the following steps:
s1) respectively weighing 5-10% of potassium feldspar, 30-40% of albite, 1-3% of calcined kaolin, 2-3% of zinc oxide, 4-8% of water-washed kaolin, 8-12% of calcined talc, 4-6% of strontium carbonate, 4-6% of calcite, 10-15% of alumina and 5-8% of dolomite according to the weight percentage, uniformly mixing, adding a proper amount of hydration slurry, and detecting that the total content of alumina meets a set range to prepare a mixture;
s2) putting the mixture into a ball mill for wet ball milling to prepare slurry;
s3) screening the slurry through a vibrating screen, and removing iron through strong magnetism to obtain the glaze slip of the protective glaze.
Preferably, in step S2), the flow rate of the wet ball milling is 90 to 120 seconds, and the ball milling time is 10 to 11 hours; the fineness of the slurry is 325 meshes of residual 0.1-0.3 g/proportion cup.
Preferably, the specific gravity of the slurry prepared in step S2) is 1.80 to 1.86 g/ml.
Preferably, in step S3), the aperture of the vibrating screen is 160 meshes.
The technical scheme of the invention has the beneficial effects that: the total content of alumina in the protective glaze is up to 23-26%, the viscosity of the protective glaze in a high-temperature molten state is higher than that of the conventional glaze in the prior art, and the tension of the protective glaze effectively inhibits the glaze layer from being broken by bubbles generated in a cover glaze layer and a blank body of the conventional glaze below, so that the defects of air holes and recessed glaze are avoided on the surface of the protective glaze, and the unqualified products in batches are avoided.
Furthermore, the invention provides a ceramic tile using the protective glaze suitable for being fired in the low-temperature fast firing kiln, the adopted overglaze and the glaze polishing are both conventional glaze materials, the protective glaze is distributed above the ink jet layer between the overglaze and the glaze polishing, the thickness is small, bubbles can be effectively prevented from rising, and the ceramic tile has the effect of protecting the ink jet layer and the glaze surface from generating air holes and recessed glaze defects.
The invention also provides a preparation method of the protective glaze suitable for being fired in the low-temperature fast-firing kiln, which has simple process and can not cause the obvious increase of the manufacturing cost of products.
Detailed Description
In the description herein, references to the description of "an embodiment," "an example" or the like are intended to mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
While embodiments of the invention have been shown and described, it will be understood by those of ordinary skill in the art that: various changes, modifications, substitutions and alterations can be made to the embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.
The technical solution of the present invention will be further described with reference to the following embodiments.
A protective glaze suitable for being fired in a low-temperature fast-firing kiln comprises the following raw materials in percentage by weight: SiO 22 45-49wt％、Al2O3 23-26wt％、CaO 2.5-4wt％、MgO 4-6wt％、K2O 0.5-1.5wt％、Na24-4 wt% of O3 and 14-18 wt% of loss on ignition;
the thickness of the protective glaze is 0.05-0.06mm, the sintering temperature of the protective glaze in the low-temperature fast-sintering kiln is 1185-1235 ℃, and the sintering time is 50-55 min.
The total content of the alumina in the protective glaze reaches 23-26%, and the tension of the protective glaze can effectively inhibit bubbles generated in a overglaze layer and a blank body from breaking through the glaze layer, so that the defects of pores and recessed glaze are avoided for the protective glaze, and further the unqualified products in batches are avoided.
The protective glaze can be glazed by adopting a nozzle atomization method of a water jet cutter, the specific gravity of the applied protective glaze can be reduced, a thin protective layer with the thickness of only 0.05-0.06mm is formed on the surface of the ink jet layer uniformly distributed above the brick body, and the pattern of the ink jet layer can be prevented from being damaged.
The firing cycle of the kiln is 50-55 minutes, which is shorter than that of the conventional kiln and the firing temperature range is narrow, so the kiln is called a low-temperature fast firing kiln.
If the content of the aluminum oxide in the protective glaze is higher than 26%, the phenomena of poor product transparency and opacification of a glaze layer can be generated, and the color development of the glaze and the antifouling performance of the glaze are influenced; on the contrary, if the content of alumina in the protective glaze is less than 23%, the effect of preventing bubbles from rising to protect the ink-jet layer and the glaze surface from generating pores and recessed glaze defects is not achieved.
Because the ink is an oily substance, the protective glaze layer is sprayed on the surface of the ink-jet layer, glaze shrinkage caused by direct contact of the glaze polishing layer and the ink can be avoided, and an effective isolation effect is achieved.
Specifically, the raw materials of the protective glaze comprise, by weight, 5-10% of potassium feldspar, 30-40% of albite, 1-3% of calcined kaolin, 2-3% of zinc oxide, 4-8% of water-washed kaolin, 8-12% of calcined talc, 4-6% of strontium carbonate, 4-6% of calcite, 10-15% of alumina and 5-8% of dolomite.
By supplementing 10-15 wt% of alumina and controlling the total content of alumina in the formula of the protective glaze to be 23-26 wt%, the viscosity of the protective glaze layer during high-temperature melting is ensured, so that the effects of inhibiting bubbles to protect the ink-jet layer and the glaze surface are achieved, and the phenomena of poor transparency and opacification of the glaze layer are avoided.
Calcite and dolomite, the loss on ignition of the two materials is large, the high-temperature viscosity is small, and the two materials need to be reasonably matched in the formula in order to ensure the sintering degree and the transparency of the protective glaze.
Further, the initial melting temperature of the protective glaze is 1210-1220 ℃.
The initial melting temperature of the protective glaze refers to the initial melting temperature of the pure protective glaze. If the protective glaze and the polishing glaze in the middle layer are combined at high temperature, the initial melting temperature of the mixture is reduced by about 25-30 ℃.
Further, the invention also provides a ceramic tile fired by the low-temperature fast-firing kiln, which sequentially comprises a green brick, a cover glaze layer, an ink spraying layer, a protective glaze layer and a glaze polishing layer from bottom to top, wherein the protective glaze layer is the protective glaze suitable for firing the ceramic tile by the low-temperature fast-firing kiln; the thickness of the protective glaze layer is greater than that of the ink spraying layer, and the thickness of the protective glaze layer is 0.01-0.02 time of that of the overglaze layer;
the glaze used for the overglaze layer is a conventional glaze with the content of aluminum oxide of 13-15 wt% respectively;
the glaze used for the glaze polishing layer is a conventional glaze with the alumina content of 13-15 wt%;
when the average gray scale of the ink-jet layer is less than or equal to 50 ℃, the surface temperature of the firing area of the low-temperature fast firing kiln is 1200 +/-5 ℃, and the bottom temperature of the firing area of the low-temperature fast firing kiln is 1230 +/-5 ℃.
The ceramic tile fired by the low-temperature fast firing kiln adopts the protective glaze which is matched with the overglaze and the glaze polishing which are both conventional glaze materials, the protective glaze is distributed above the ink jet layer between the overglaze and the glaze polishing, the thickness is small, the viscosity of the protective glaze in a high-temperature melting state is higher than that of the overglaze, bubbles can be effectively prevented from rising, and the ceramic tile has the effect of protecting the ink jet layer and the glaze surface from generating air holes and recessed glaze defects.
Different ceramic tile products have different ink amounts, different average gray scales of the ink-jet layer and different heat absorption capacities of the ink-jet layer in the firing process, so that the firing temperature needs to be adjusted according to the average gray scale of the ink-jet layer, thereby protecting the ink-jet layer and reducing pinholes and recessed glaze generation on the tile surface.
Preferably, when the average gray scale of the ink jet layer is greater than 50, the surface temperature of the firing zone of the low-temperature rapid firing kiln is 1190 +/-5 ℃, and the bottom temperature of the firing zone of the low-temperature rapid firing kiln is 1227 +/-5 ℃.
The gray levels of the ink-jet layers are different, and the heat absorption capacity is different, so that the firing temperature needs to be adjusted differently by taking the average gray level 50 of the ink-jet layers as a boundary, so that the ink-jet layers are prevented from being damaged by bubbles, and the display precision of the ink-jet layers on the glaze surface is improved.
Preferably, when the average gray scale of the ink-jet layer is less than or equal to 50, the specific gravity of the protective glaze is 1.38 +/-0.02 g/ml, and the glazing amount of the corresponding protective glaze applied is 45-50 g/square meter; when the average gray scale of the ink-jet layer is more than 50, the specific gravity of the applied protection glaze is 1.33 +/-0.02 g/ml, and the corresponding glazing amount of the protection glaze is 32-35 g/square meter.
The dark color product has large ink amount, large heat absorption amount in the firing process, and the specific weight and the glazing amount of the protective glaze are adjusted, so that the effects of effectively protecting the ink spraying layer and reducing pinholes and concave glaze on the surface of the brick are achieved.
The gray level of the ink-jet layer is large, the color of the product is dark, the product is easy to absorb heat when entering a kiln for sintering, and the temperature of a hearth is easy to cause the product to be heated and over-sintered, so that the sintering temperature for producing the product with large gray level needs to be properly reduced; in addition, because the ink is an oily substance, the product with large gray scale is easy to generate powder on the surface of the brick due to rapid water collection in the glaze line glaze distribution process, so that the uneven distribution is caused, and therefore, the specific gravity and the glazing amount of the protective glaze of the product with large gray scale need to be properly reduced.
Further, the invention also provides a preparation method of the protective glaze suitable for being fired in the low-temperature fast-firing kiln, which comprises the following steps:
S1) respectively weighing 5-10% of potassium feldspar, 30-40% of albite, 1-3% of calcined kaolin, 2-3% of zinc oxide, 4-8% of water-washed kaolin, 8-12% of calcined talc, 4-6% of strontium carbonate, 4-6% of calcite, 10-15% of alumina and 5-8% of dolomite according to the weight percentage, uniformly mixing, adding a proper amount of hydration slurry, and detecting that the total content of alumina meets a set range to prepare a mixture;
s2) putting the mixture into a ball mill for wet ball milling to prepare slurry;
s3) screening the slurry through a vibrating screen, and removing iron through strong magnetism to obtain the glaze slurry of the protective glaze.
The preparation process is simple, and the manufacturing cost of the product is not obviously increased.
Preferably, in step S2), the flow rate of the wet ball milling is 90 to 120 seconds, and the ball milling time is 10 to 11 hours; the fineness of the slurry is 325 meshes of residual 0.1-0.3 g/proportion cup.
If the flow rate of the slurry is higher than 120 seconds, the ball milling efficiency is reduced, and the formula is not influenced; if the time is less than 90 seconds, the effect of ball milling cannot be achieved.
If the surplus is higher than 0.3 g/proportion cup, the penetration of the glaze layer is affected, and a gun nozzle is easily blocked during glaze spraying; if the screen residue is less than 0.1 g/specific gravity cup, the power consumption of ball milling is increased.
Preferably, the specific gravity of the slurry prepared in step S2) is 1.80 to 1.86 g/ml.
The specific gravity of the slurry is 1.80-1.86g/ml which is higher than that of the applied protective glaze, and the aim is to control the specific gravity of the sprayed glaze slurry of the protective glaze to be in a required range by adding water for dilution during later use.
Preferably, in step S3), the aperture of the vibrating screen is 160 meshes.
The iron-containing metal impurities in the slurry can be fully removed through the vibrating screen with the aperture larger than that of the slurry particles, and the service life of the product is prolonged.
Examples 1 to 5 and comparative examples 1 to 6
1. The protective glaze suitable for being fired in a low-temperature fast-firing kiln in each example and each proportion is prepared according to the following steps:
s1) respectively weighing 5-10% of potassium feldspar, 30-40% of albite, 1-3% of calcined kaolin, 2-3% of zinc oxide, 4-8% of water-washed kaolin, 8-12% of calcined talc, 4-6% of strontium carbonate, 4-6% of calcite, 10-15% of alumina and 5-8% of dolomite according to the weight percentage, uniformly mixing, adding a proper amount of hydration slurry, and detecting that the total content of alumina meets a set range to prepare a mixture;
s2) putting the mixture into a ball mill for wet ball milling to prepare slurry;
s3) sieving the slurry by a vibrating screen of 160 meshes, and removing iron by strong magnetism to obtain glaze slurry of the protective glaze;
In the step S2), the flow rate of wet ball milling is 90-120 seconds, and the ball milling time is 10-11 hours; the specific gravity of the slurry is 1.80-1.86g/ml, and the fineness of the slurry is 325 meshes and the residual is 0.1-0.3 g/specific gravity cup; the specific gravity of the prepared slurry is 1.80-1.86 g/ml.
2. The ceramic tiles of the examples and comparative examples were prepared according to the following procedure:
t1) taking a brick blank, spraying a ground coat on the surface of the brick blank, spraying a cover coat after the ground coat is dried, and printing a pattern layer on the surface of the dried cover coat by using an ink-jet printer to obtain the brick blank with the pattern layer;
t2), confirming the gray level of the printed ink-jet layer, diluting the protective glaze prepared in the embodiment or the comparative example with water to a set specific gravity, spraying the corresponding diluted protective glaze on the surface of the green brick with the pattern layer by a water jet machine by adopting a nozzle atomization method, and then spraying and polishing the glaze to prepare the ceramic tile to be fired;
t3) placing the ceramic tiles to be fired into the low-temperature fast firing kiln for firing for 50-55 min;
in the step T1), the glaze used for the overglaze layer is a conventional glaze with the alumina content of 13-15 wt% respectively; the glaze used for the glaze polishing layer is a conventional glaze with the alumina content of 23-26 wt%;
In the step T2), when the average gray scale of the ink-jet layer is less than or equal to 50, the specific gravity of the protection glaze is 1.38 +/-0.02 g/ml, and the glazing amount of the corresponding protection glaze applied is 45-50 g/square meter; when the average gray scale of the ink-jet layer is more than 50, the specific gravity of the applied protection glaze is 1.33 +/-0.02 g/ml, and the corresponding glazing amount of the protection glaze is 32-35g per square meter;
in the step T3), when the average gray scale of the ink-jet layer is less than or equal to 50, the surface temperature of the firing area of the low-temperature fast firing kiln is 1200 +/-5 ℃, and the bottom temperature of the firing area of the low-temperature fast firing kiln is 1230 +/-5 ℃; and when the average gray scale of the ink-jet layer is more than 50 ℃, the surface temperature of the firing zone of the low-temperature rapid-firing kiln is 1190 +/-5 ℃, and the bottom temperature of the firing zone of the low-temperature rapid-firing kiln is 1227 +/-5 ℃.
3. The raw material components and ratios, and process parameters of each example and comparative example are detailed in tables 1 and 2.
4. The number of pinholes of the glaze of the products of each example and comparative example was checked according to the following detection method, and at the same time, whether the appearance of the glaze had an unacceptable defect was checked, wherein the pinhole detection method: visually inspecting the number of pinholes of the glaze surface at a distance of 0.5m, wherein the quality standard is that the diameter phi of the pinholes of the monolithic tile is less than or equal to 0.5mm and the monolithic tile is not dense; 0.5mm < diameter phi of pinhole <1 mm; thirdly, the diameter phi of the pinhole is not allowed to be more than or equal to 1 mm; the results are shown in tables 1 and 2.
TABLE 1 raw Material composition, Process parameters and test results of the examples
Table 2 raw material composition, process parameters and test results for each ratio
The data information from tables 1 and 2 above was analyzed as follows:
1. the ceramic tiles prepared in the embodiments 1 to 5 have the number of the pinholes of the glaze surface meeting the requirements of quality standards, and the transparency and color of the glaze surface are qualified and free of defects, which indicates that the pinhole eliminating effect of the protective glaze suitable for the low-temperature fast-firing kiln to fire the ceramic tiles of the invention meets the expected target, and the technical scheme is effective.
2. In contrast to example 4, comparative example 1 differs in that: the addition amount of the alumina in the comparative example 1 exceeds the upper limit value of 15 wt%, which affects the transparency of the glaze layer, so that the transparency of the glaze layer of the ceramic tile in the comparative example 1 is insufficient and the product is unqualified although the quantity of pinholes of the glaze layer meets the quality requirement.
3. In contrast to example 4, comparative example 2 differs in that: the addition amount of the alumina in the comparative example 2 is lower than the lower limit value of 10%, the high-temperature viscosity of the protective glaze is insufficient, the effect of blocking bubbles is poor, the diameter phi of pinholes of the glaze surface of the ceramic tile in the comparative example 2 is larger than or equal to 1mm and is dense, and the product is unqualified.
4. In contrast to example 4, comparative example 3 differs in that: the temperature value of the surface temperature of the firing temperature of the comparative example 3 is 1240 +/-5 ℃, the highest temperature reaches 1245 ℃ and is higher than the upper limit value of 1227 +5 ℃, so that the protective glaze layer of the ceramic tile of the comparative example 3 fails during high-temperature firing, the glaze is damaged by bubbles, the diameter phi of air holes and pinholes of the glaze is larger than or equal to 1mm and dense, the glaze has the defect of unevenness, and the product is unqualified.
5. Comparative example 4 differs from example 4 in that: the temperature value of the surface temperature of the firing temperature of the comparative example 4 is 1220 ℃ +/-5 ℃, and the lowest temperature of 1225 ℃ is lower than the lower limit value of 1227 ℃ -5 ℃, so that the glaze layer of the glaze surface of the comparative example 4 is not fired, is not permeable, and is unqualified.
6. Comparative example 5 differs from example 4 in that: the spraying amount of the protective glaze of the comparative example 5 is too small, only 20 g/square meter is less than the lower limit value of 32 g/square meter, the effect of the protective glaze on blocking bubbles is insufficient, the diameter phi of pinholes of the glaze surface of the ceramic tile of the comparative example 5 is larger than or equal to 1mm and is dense, and the product is unqualified.
7. In contrast to example 4, comparative example 6 differs in that: the spraying amount of the protective glaze of the comparative example 6 is 50 g/square meter which exceeds the upper limit value of 35 g/square meter, the transparency of the glaze layer is influenced, the number of pinholes of the glaze surface of the ceramic tile of the comparative example 6 meets the quality requirement, but the glaze surface is opaque, the defect of unclear patterns exists, and the product is unqualified.
In summary, the effects of the embodiments of the present invention are: the total content of the alumina in the protective glaze reaches 23-26%, the viscosity of the protective glaze in a high-temperature molten state is higher than that of the conventional glaze in the prior art, and the tension of the protective glaze can effectively inhibit bubbles generated in a cover glaze layer and a blank body of the conventional glaze below from breaking through the glaze layer, so that the defects of air holes and recessed glaze of the glaze layer are avoided, and further, the unqualified products in batches are avoided.
Furthermore, the invention provides a ceramic tile using the protective glaze suitable for being fired in the low-temperature fast firing kiln, the adopted overglaze and the glaze polishing are both conventional glaze materials, the protective glaze is distributed above the ink jet layer between the overglaze and the glaze polishing, the thickness is small, bubbles can be effectively prevented from rising, and the ceramic tile has the effect of protecting the ink jet layer and the glaze surface from generating air holes and recessed glaze defects.
The invention also provides a preparation method of the protective glaze suitable for being fired in the low-temperature fast-firing kiln, which has simple process and can not cause the obvious increase of the manufacturing cost of products.
In the description herein, references to the description of the term "one embodiment," "some embodiments," "an illustrative embodiment," "an example," "a specific example," or "some examples" or the like mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
While embodiments of the present invention have been shown and described, it will be understood by those of ordinary skill in the art that: various changes, modifications, substitutions and alterations can be made to the embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.
The technical principle of the present invention is described above in connection with specific embodiments. The description is only intended to explain the principles of the invention; and should not be construed as limiting the scope of the invention in any way. Based on the explanations herein; other embodiments of the invention will occur to those skilled in the art without the exercise of inventive faculty; all of which fall within the scope of the present invention.
Claims (10)
1. The protective glaze suitable for being fired in a low-temperature fast-firing kiln is characterized by comprising the following raw materials in percentage by weight: SiO 2245-49wt％、Al2O323-26wt％、CaO2.5-4wt％、MgO 4-6wt％、K2O 0.5-1.5wt％、Na2O3-4 wt% and loss on ignition 14-18 wt%;
the coating thickness of the protective glaze is 0.05-0.06mm, the firing temperature of the protective glaze in the low-temperature fast firing kiln is 1185-1235 ℃, and the firing time is 50-55 min.
2. The protective glaze suitable for being fired in a low-temperature fast-firing kiln as claimed in claim 1, wherein the raw materials of the protective glaze comprise, by weight, 5-10% of potassium feldspar, 30-40% of albite, 1-3% of calcined kaolin, 2-3% of zinc oxide, 4-8% of water-washed kaolin, 8-12% of calcined talc, 4-6% of strontium carbonate, 4-6% of calcite, 10-15% of alumina and 5-8% of dolomite.
3. The protective glaze suitable for low-temperature fast-firing kiln firing according to claim 1, wherein the onset temperature of the protective glaze is 1210 ℃ to 1220 ℃.
4. A low-temperature fast-firing kiln-fired ceramic tile, which is characterized by comprising a tile blank, a cover glaze layer, an ink spraying layer, a protective glaze layer and a glaze polishing layer from bottom to top, wherein the protective glaze layer uses the protective glaze suitable for being fired in the low-temperature fast-firing kiln as claimed in any one of claims 1 to 3; the thickness of the protective glaze layer is greater than that of the ink spraying layer, and the thickness of the protective glaze layer is 0.01-0.02 time of that of the overglaze layer;
the glaze used for the overglaze layer is a conventional glaze with the aluminum oxide content of 13-15 wt% respectively;
the glaze used for the glaze polishing layer is a conventional glaze with the alumina content of 23-26 wt%;
when the average gray scale of the ink-jet layer is less than or equal to 50 ℃, the surface temperature of the firing area of the low-temperature fast firing kiln is 1200 +/-5 ℃, and the bottom temperature of the firing area of the low-temperature fast firing kiln is 1230 +/-5 ℃.
5. The low-temperature fast-firing kiln-fired ceramic tile according to claim 4, wherein when the average gray scale of the ink jet layer is > 50, the surface temperature of the firing zone of the low-temperature fast-firing kiln is 1190 ± 5 ℃, and the bottom temperature of the firing zone of the low-temperature fast-firing kiln is 1227 ± 5 ℃.
6. The ceramic tile fired by the low-temperature fast firing kiln according to claim 5, wherein when the average gray level of the ink-jet layer is less than or equal to 50, the specific gravity of the protective glaze is 1.38 plus or minus 0.02g/ml, and the glazing amount of the corresponding protective glaze applied is 45-50 g/square meter; when the average gray scale of the ink-jet layer is more than 50, the specific gravity of the applied protection glaze is 1.33 +/-0.02 g/ml, and the corresponding glazing amount of the protection glaze is 32-35 g/square meter.
7. The method for preparing a protective glaze suitable for low-temperature fast-firing kiln firing according to any one of claims 1 to 3, characterized by comprising the steps of:
s1) respectively weighing 5-10% of potassium feldspar, 30-40% of albite, 1-3% of calcined kaolin, 2-3% of zinc oxide, 4-8% of water-washed kaolin, 8-12% of calcined talc, 4-6% of strontium carbonate, 4-6% of calcite, 10-15% of alumina and 5-8% of dolomite according to the weight percentage, uniformly mixing, adding a proper amount of hydration slurry, and detecting that the total content of alumina meets a set range to prepare a mixture;
s2) putting the mixture into a ball mill for wet ball milling to prepare slurry;
s3) screening the slurry through a vibrating screen, and removing iron through strong magnetism to obtain the glaze slip of the protective glaze.
8. The method for preparing a protective glaze suitable for low-temperature fast-firing kiln as claimed in claim 7, wherein in step S2), the flow rate of wet ball milling is 90-120 seconds, and the ball milling time is 10-11 hours; the fineness of the slurry is 325 meshes and the residual is 0.1-0.3 g/specific gravity cup.
9. The method for preparing a protective glaze suitable for low-temperature fast-firing kiln firing according to claim 7, wherein the specific gravity of the slurry prepared in step S2) is 1.80-1.86 g/ml.
10. The method for preparing a protective glaze suitable for low-temperature fast-firing kiln as claimed in claim 7, wherein in step S3), the aperture of the vibrating screen is 160 meshes.
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