Method for manufacturing ceramic tiles decorated with dry particle inks

Abstract

The present disclosure relates to the field of ceramic tiles, in particular, to a ceramic tile decorated with a dry particle ink and a manufacturing method thereof. The manufacturing method comprises the steps of A: decorating a ground coat; B: decorating to form a pattern; C: drying firstly; D: embellishing with dry particles; E: spraying a protective glaze; and F: firing. The manufacturing method has simple operation steps and convenient control, simplifies the process flow, improves production efficiency, and reduces production difficulty and production cost. By spraying with the dry particle ink, jet printing is carried out on a designated position on the surface of a green body, so that the texture sprayed can accurately correspond to the pattern-decorated texture, and the uniformity and adhesion of the dry particle distribution on the surface of the green body can be improved.

Claims

1. A method for manufacturing a ceramic tile decorated with a dry particle ink, wherein the method comprises A: glazing a surface of a green body with a ground coat; B: maintaining a temperature of the green body at 40-60? C. after the green body is glazed with the ground coat of step A; then, decorating a surface of the ground coat of the green body to form a pattern; C: performing a first drying on the green body after the green body is decorated with the pattern of step B; D: embellishing the green body with dry particles by spreading the dry particle ink on the surface of the green body after the first drying of step C; then, performing a second drying; E: spraying a protective glaze on the surface of the green body after the second drying of step D; and F: firing the green body after the green body is sprayed with the protective glaze of step E to produce the ceramic tile, the ceramic tile is decorated with the dry particles and has a three-dimensional pattern, wherein in step D, the dry particle ink comprises the following raw materials in parts by weight: TABLE-US-00035 dry particles 30-40 parts, a dispersant 5-10 parts, a viscosity modifier 0.05-0.15 parts, a surfactant 0.2-0.3 parts, an excipient 2-5 parts, a solvent 60-80 parts.

2. The method according to claim 1, wherein in step C, a temperature of the first drying is from 120? C. to 150? C.; wherein in step D, a quantity of the dry particle ink is from 2 kg/m.sup.2 to 3 kg/m.sup.2; wherein in step D, a temperature of the second drying is from 120? C. to 150? C.

3. The method according to claim 1, wherein each part of the dispersant comprises 3-8 parts of polyethylene glycol, 10-12 parts of polyacrylamide, and 2-5 parts of polyacrylate; each part of the viscosity modifier comprises 20-30 parts of acrylic resin, 5-10 parts of polyethylene glycol methyl ether, and 5-10 parts of ethanol; the surfactant is at least one selected from the group consisting of sodium lauryl sulfate, octylphenol polyoxyethylene ether, fatty acid polyoxyethylene ester, dodecyltrimethylammonium bromide and ethoxylated fatty acid sorbitan ester.

4. The method according to claim 1, wherein each part of the excipient comprises 0.5-1.5 parts of a pH regulator, 1-2 parts of a dryer, and 0.5-1.0 parts of a preservative; the pH regulator is at least one selected from the group consisting of trimethylamine, triethanolamine and ammonia water; the dryer is a mixture consisting of ethanol and isopropanol at a weight ratio of 1:3-4; the preservative is at least one selected from the group consisting of 2,2-dihydroxy-5,5-dichlorodiphenylmethane, chloroacetamide, sodium o-phenylphenol, 2-hydroxy biphenyl, and N-(2-hydroxy propyl) aminomethanol; each part of the solvent is a mixture consisting of ethylene glycol butyl ether acetate, dipropylene glycol dimethyl ether, and propylene glycol methyl ether at a weight ratio of 3-4:1:1.5-2.5.

5. The method according to claim 1, wherein in step E, the protective glaze is a matte transparent protective glaze, the matte transparent protective glaze comprises the following raw materials in parts by weight: TABLE-US-00036 calcined zinc oxide 5-6 parts, barium carbonate 6-8 parts, potash feldspar 15-20 parts, a frit 35-45 parts, calcined alumina 5-10 parts, burnt talc 10-14 parts, dolomite 1-5 parts, kaolin 6-8 parts, an ultrafine quartz powder 1-3 parts.

6. The method according to claim 1, wherein in step E, the spraying of the protective glaze is carried out by high-pressure spraying, a pressure of the high-pressure spraying is 10-20 bar, an amount of the protective glaze sprayed is 70-100 g/m.sup.2; wherein in step F, the firing is carried out at 1180-1220? C. for 60-80 min.

Description

DETAILED DESCRIPTION OF PREFERRED EXAMPLES

(1) In order to facilitate understanding of those skilled in the art, the present disclosure will be further described below through examples, and the content mentioned in the examples does not limit the present disclosure.

Example 1

(2) A method for manufacturing a ceramic tile decorated with a dry particle ink, wherein the method comprised A: glazing a surface of a green body with a ground coat; B: maintaining a temperature of the green body at 40? Cafter the green body was glazed with the ground coat of step A; then, decorating a surface of the ground coat of the green body to form a pattern; C: performing a first drying on the green body after the green body was decorated with the pattern of step B; D: embellishing the green body with dry particles by spreading the dry particle ink on the surface of the green body after the first drying of step C; then, performing a second drying; E: spraying a protective glaze on the surface of the green body after the second drying of step D; and F: firing the green body after the green body was sprayed with the protective glaze of step E to produce the ceramic tile, the ceramic tile was decorated with the dry particles and had a three-dimensional pattern.

(3) Before step A, the green body was decorated with line textures by means of a digital material distribution method using mechanical arms.

(4) In step A, the ground coat comprised the following chemical components:

(5) TABLE-US-00005 SiO.sub.2 .sup.65% Al.sub.2O.sub.3 18.5% Fe.sub.2O.sub.3 0.15% CaO 1.35% MgO 0.7% K.sub.2O 2.8% Na.sub.2O 3.35% TiO.sub.2 0.08% ZrO.sub.2 2.17% BaO 4.90% ZnO 1.0%.

(6) In step C, a temperature of the first drying was 120? C.; wherein in step D, a quantity of the dry particle ink was 2 kg/m.sup.2; wherein in step D, a temperature of the second drying was 120? C.

(7) In step E, the spraying of the protective glaze was carried out by high-pressure spraying, a pressure of the high-pressure spraying was 10 bar, an amount of the protective glaze sprayed was 70 g/m.sup.2; wherein in step F, the firing was carried out at 1180? C. for 80 min.

(8) In step D, the dry particle ink comprised the following raw materials in parts by weight:

(9) TABLE-US-00006 dry particles 30 parts, a dispersant 5 parts, a viscosity modifier 0.05 parts, a surfactant 0.2 parts, an excipient 2 parts, a solvent 60 parts.

(10) Each part of the dispersant comprised 3 parts of polyethylene glycol, 10 parts of polyacrylamide, and 2 parts of polyacrylate; each part of the viscosity modifier comprised 20 parts of acrylic resin, 5 parts of polyethylene glycol methyl ether, and 5 parts of ethanol; the surfactant was sodium lauryl sulfate.

(11) Each part of the excipient comprised 0.5 parts of a pH regulator, 1 part of a dryer, and 0.5 parts of a preservative; the pH regulator was trimethylamine; the dryer was a mixture consisting of ethanol and isopropanol at a weight ratio of 1:3; the preservative was sodium o-phenylphenol; each part of the solvent was a mixture consisting of ethylene glycol butyl ether acetate, dipropylene glycol dimethyl ether, and propylene glycol methyl ether at a weight ratio of 3:1:1.5.

(12) In step E, the protective glaze was a matte transparent protective glaze, the matte transparent protective glaze comprised the followings raw materials in parts by weight:

(13) TABLE-US-00007 calcined zinc oxide 5 parts, barium carbonate 6 parts, potash feldspar 15 parts, a frit 35 parts, calcined alumina 5 parts, burnt talc 10 parts, dolomite 1 part, kaolin 6 parts, an ultrafine quartz powder 1 part.

(14) The frit comprised the following chemical components:

(15) TABLE-US-00008 SiO.sub.2 45.25% Al.sub.2O.sub.3 .sup.19% Fe.sub.2O.sub.3 0.10% CaO 2.45% MgO 0.75% K.sub.2O 2.0% Na.sub.2O 4.8% TiO.sub.2 0.26% B.sub.2O.sub.3 0.04% BaO 15.4% ZnO 6.5% SrO 3.8%.

(16) A ceramic tile decorated with dry particles prepared by the method above, wherein the ceramic tile decorated with dry particles comprised, from bottom to top, a green body layer, a ground coat layer, a pattern layer, a dry particle ink layer and a protective glaze layer; a thickness of the ground coat layer was 0.05-0.2 mm, a thickness of the pattern layer was 0.05-0.1 mm, a thickness of the dry particle ink layer was 0.5-1 mm, and a thickness of the protective glaze layer was 0.02-0.03 mm.

Example 2

(17) A method for manufacturing a ceramic tile decorated with a dry particle ink, wherein the method comprised A: glazing a surface of a green body with a ground coat; B: maintaining a temperature of the green body at 45? Cafter the green body was glazed with the ground coat of step A; then, decorating a surface of the ground coat of the green body to form a pattern; C: performing a first drying on the green body after the green body was decorated with the pattern of step B; D: embellishing the green body with dry particles by spreading the dry particle ink on the surface of the green body after the first drying of step C; then, performing a second drying; E: spraying a protective glaze on the surface of the green body after the second drying of step D; and F: firing the green body after the green body was sprayed with the protective glaze of step E to produce the ceramic tile, the ceramic tile was decorated with the dry particles and had a three-dimensional pattern.

(18) Before step A, the green body was decorated with line textures by means of a digital material distribution method using mechanical arms.

(19) In step A, the ground coat comprised the following chemical components:

(20) TABLE-US-00009 SiO.sub.2 .sup.66% Al.sub.2O.sub.3 .sup.19% Fe.sub.2O.sub.3 0.13% CaO 1.33% MgO 0.68% K.sub.2O 2.6% Na.sub.2O 3.23% TiO.sub.2 0.11% ZrO.sub.2 1.06% BaO 4.88% ZnO 0.98%.

(21) In step C, a temperature of the first drying was 130? C.; wherein in step D, a quantity of the dry particle ink was 2.2 kg/m.sup.2; wherein in step D, a temperature of the second drying was 128? C.

(22) In step E, the spraying of the protective glaze was carried out by high-pressure spraying, a pressure of the high-pressure spraying was 12 bar, an amount of the protective glaze sprayed was 80 g/m.sup.2; wherein in step F, the firing was carried out at 1190? C. for 65 min.

(23) In step D, the dry particle ink comprised the following raw materials in parts by weight:

(24) TABLE-US-00010 dry particles 32 parts, a dispersant 6 parts, a viscosity modifier 0.08 parts, a surfactant 0.23 parts, an excipient 3 parts, a solvent 65 parts.

(25) Each part of the dispersant comprised 4 parts of polyethylene glycol, 10.5 parts of polyacrylamide, and 3 parts of polyacrylate; each part of the viscosity modifier comprised 22 parts of acrylic resin, 6 parts of polyethylene glycol methyl ether, and 6 parts of ethanol; the surfactant was octylphenol polyoxyethylene ether.

(26) Each part of the excipient comprised 0.8 parts of a pH regulator, 1.2 parts of a dryer, and 0.6 parts of a preservative; the pH regulator was trimethylamine; the dryer was a mixture consisting of ethanol and isopropanol at a weight ratio of 1:3.2; the preservative was chloroacetamide; each part of the solvent was a mixture consisting of ethylene glycol butyl ether acetate, dipropylene glycol dimethyl ether, and propylene glycol methyl ether at a weight ratio of 3.2:1:1.8.

(27) In step E, the protective glaze was a matte transparent protective glaze, the matte transparent protective glaze comprised the following aw materials in parts by weight:

(28) TABLE-US-00011 calcined zinc oxide 5.2 parts, barium carbonate 6.5 parts, potash feldspar 16 parts, a frit 38 parts, calcined alumina 6 parts, burnt talc 11 parts, dolomite 2 parts, kaolin 6.5 parts, an ultrafine quartz powder 1.5 parts.

(29) The frit comprised the following chemical components:

(30) TABLE-US-00012 SiO.sub.2 45.5% Al.sub.2O.sub.3 .sup.19% Fe.sub.2O.sub.3 0.09% CaO 2.60% MgO 1.01% K.sub.2O 1.90% Na.sub.2O 4.6% TiO.sub.2 0.25% B.sub.2O.sub.3 0.05% BaO 15.1% ZnO 6.2% SrO 3.7%.

(31) A ceramic tile decorated with dry particles prepared by the method above, wherein the ceramic tile decorated with dry particles comprised, from bottom to top, a green body layer, a ground coat layer, a pattern layer, a dry particle ink layer and a protective glaze layer; a thickness of the ground coat layer was 0.05-0.2 mm, a thickness of the pattern layer was 0.05-0.1 mm, a thickness of the dry particle ink layer was 0.5-1 mm, and a thickness of the protective glaze layer was 0.02-0.03 mm.

Example 3

(32) A method for manufacturing a ceramic tile decorated with a dry particle ink, wherein the method comprised A: glazing a surface of a green body with a ground coat; B: maintaining a temperature of the green body at 50? Cafter the green body was glazed with the ground coat of step A; then, decorating a surface of the ground coat of the green body to form a pattern; C: performing a first drying on the green body after the green body was decorated with the pattern of step B; D: embellishing the green body with dry particles by spreading the dry particle ink on the surface of the green body after the first drying of step C; then, performing a second drying; E: spraying a protective glaze on the surface of the green body after the second drying of step D; and F: firing the green body after the green body was sprayed with the protective glaze of step E to produce the ceramic tile, the ceramic tile was decorated with the dry particles and had a three-dimensional pattern.

(33) Before step A, the green body was decorated with line textures by means of a digital material distribution method using mechanical arms.

(34) In step A, the ground coat comprised the following chemical components:

(35) TABLE-US-00013 SiO.sub.2 .sup.65% Al.sub.2O.sub.3 .sup.20% Fe.sub.2O.sub.3 0.12% CaO 1.31% MgO 0.64% K.sub.2O 2.4% Na.sub.2O 3.21% TiO.sub.2 0.10% ZrO.sub.2 1.5% BaO 4.82% ZnO 0.90%.

(36) In step C, a temperature of the first drying was 135? C.; wherein in step D, a quantity of the dry particle ink was 2.5 kg/m.sup.2; wherein in step D, a temperature of the second drying was 135? C.

(37) In step E, the spraying of the protective glaze was carried out by high-pressure spraying, a pressure of the high-pressure spraying was 15 bar, an amount of the protective glaze sprayed was 85 g/m.sup.2; wherein in step F, the firing was carried out at 1200? C. for 70 min.

(38) In step D, the dry particle ink comprised the following raw materials in parts by weight:

(39) TABLE-US-00014 dry particles 35 parts, a dispersant 8 parts, a viscosity modifier 0.10 parts, a surfactant 0.25 parts, an excipient 3.5 parts, a solvent 70 parts.

(40) Each part of the dispersant comprised 5 parts of polyethylene glycol, 11 parts of polyacrylamide, and 3.5 parts of polyacrylate; each part of the viscosity modifier comprised 25 parts of acrylic resin, 8 parts of polyethylene glycol methyl ether, and 8 parts of ethanol; the surfactant was fatty acid polyoxyethylene ester.

(41) Each part of the excipient comprised 1 part of a pH regulator, 1.5 parts of a dryer, and 0.8 parts of a preservative; the pH regulator was triethanolamine; the dryer was a mixture consisting of ethanol and isopropanol at a weight ratio of 1:3.5; the preservative was 2,2-dihydroxy-5,5-dichlorodiphenylmethane; each part of the solvent was a mixture consisting of ethylene glycol butyl ether acetate, dipropylene glycol dimethyl ether, and propylene glycol methyl ether at a weight ratio of 3.5:1:2.0.

(42) In step E, the protective glaze was a matte transparent protective glaze, the matte transparent protective glaze comprised the following materials in parts by weight:

(43) TABLE-US-00015 calcined zinc oxide 5.5 parts, barium carbonate 7 parts, potash feldspar 18 parts, a frit 40 parts, calcined alumina 8 parts, burnt talc 12 parts, dolomite 3 parts, kaolin 7 parts, an ultrafine quartz powder 2 parts.

(44) The frit comprised the following chemical components:

(45) TABLE-US-00016 SiO.sub.2 45.75% Al.sub.2O.sub.3 19.05% Fe.sub.2O.sub.3 0.08% CaO 2.51% MgO 0.95% K.sub.2O 1.91% Na.sub.2O 4.67% TiO.sub.2 0.25% B.sub.2O.sub.3 0.06% BaO 15.19% ZnO 6.18% SrO 3.40%.

(46) A ceramic tile decorated with dry particles prepared by the method above, wherein the ceramic tile decorated with dry particles comprised, from bottom to top, a green body layer, a ground coat layer, a pattern layer, a dry particle ink layer and a protective glaze layer; a thickness of the ground coat layer was 0.05-0.2 mm, a thickness of the pattern layer was 0.05-0.1 mm, a thickness of the dry particle ink layer was 0.5-1 mm, and a thickness of the protective glaze layer was 0.02-0.03 mm.

Example 4

(47) A method for manufacturing a ceramic tile decorated with a dry particle ink, wherein the method comprised A: glazing a surface of a green body with a ground coat; B: maintaining a temperature of the green body at 55? Cafter the green body was glazed with the ground coat of step A; then, decorating a surface of the ground coat of the green body to form a pattern; C: performing a first drying on the green body after the green body was decorated with the pattern of step B; D: embellishing the green body with dry particles by spreading the dry particle ink on the surface of the green body after the first drying of step C; then, performing a second drying; E: spraying a protective glaze on the surface of the green body after the second drying of step D; and F: firing the green body after the green body was sprayed with the protective glaze of step E to produce the ceramic tile, the ceramic tile was decorated with the dry particles and had a three-dimensional pattern.

(48) Before step A, the green body was decorated with line textures by means of a digital material distribution method using mechanical arms.

(49) In step A, the ground coat comprised the following chemical components:

(50) TABLE-US-00017 SiO.sub.2 .sup.66% Al.sub.2O.sub.3 .sup.20% Fe.sub.2O.sub.3 0.11% CaO 1.30% MgO 0.61% K.sub.2O 2.2% Na.sub.2O 3.19% TiO.sub.2 0.09% ZrO.sub.2 0.8% BaO 4.80% ZnO 0.90%.

(51) In step C, a temperature of the first drying was 140? C.; wherein in step D, a quantity of the dry particle ink was 2.8 kg/m.sup.2; wherein in step D, a temperature of the second drying was 132? C.

(52) In step E, the spraying of the protective glaze was carried out by high-pressure spraying, a pressure of the high-pressure spraying was 18 bar, an amount of the protective glaze sprayed was 90 g/m.sup.2; wherein in step F, the firing was carried out at 1210? C. for 65 min.

(53) In step D, the dry particle ink comprised the following raw materials in parts by weight:

(54) TABLE-US-00018 dry particles 38 parts, a dispersant 9 parts, a viscosity modifier 0.13 parts, a surfactant 0.28 parts, an excipient 4 parts, a solvent 75 parts.

(55) Each part of the dispersant comprised 7 parts of polyethylene glycol, 11.5 parts of polyacrylamide, and 4 parts of polyacrylate; each part of the viscosity modifier comprised 28 parts of acrylic resin, 9 parts of polyethylene glycol methyl ether, and 9 parts of ethanol; the surfactant was dodecyltrimethylammonium bromide.

(56) Each part of the excipient comprised 1.3 parts of a pH regulator, 1.8 parts of a dryer, and 0.8 parts of a preservative; the pH regulator was triethanolamine; the dryer was a mixture consisting of ethanol and isopropanol at a weight ratio of 1:3.8; the preservative was 2-hydroxy biphenyl; each part of the solvent was a mixture consisting of ethylene glycol butyl ether acetate, dipropylene glycol dimethyl ether, and propylene glycol methyl ether at a weight ratio of 3.8:1:2.3.

(57) In step E, the protective glaze was a matte transparent protective glaze, the matte transparent protective glaze comprised the following raw materials in parts by weight:

(58) TABLE-US-00019 calcined zinc oxide 5.8 parts, barium carbonate 7.5 parts, potash feldspar 19 parts, a frit 43 parts, calcined alumina 9 parts, burnt talc 13 parts, dolomite 4 parts, kaolin 7.5 parts, an ultrafine quartz powder 2.5 parts.

(59) The frit comprised the following chemical components:

(60) TABLE-US-00020 SiO.sub.2 46.0% Al.sub.2O.sub.3 19.5% Fe.sub.2O.sub.3 0.06% CaO 2.35% MgO 0.77% K.sub.2O 1.85% Na.sub.2O 4.6% TiO.sub.2 0.22% B.sub.2O.sub.3 0.05% BaO 15.0% ZnO 6.1% SrO 3.5%.

(61) A ceramic tile decorated with dry particles prepared by the method above, wherein the ceramic tile decorated with dry particles comprised, from bottom to top, a green body layer, a ground coat layer, a pattern layer, a dry particle ink layer and a protective glaze layer; a thickness of the ground coat layer was 0.05-0.2 mm, a thickness of the pattern layer was 0.05-0.1 mm, a thickness of the dry particle ink layer was 0.5-1 mm, and a thickness of the protective glaze layer was 0.02-0.03 mm.

Example 5

(62) A method for manufacturing a ceramic tile decorated with a dry particle ink, wherein the method comprised A: glazing a surface of a green body with a ground coat; B: maintaining a temperature of the green body at 60? Cafter the green body was glazed with the ground coat of step A; then, decorating a surface of the ground coat of the green body to form a pattern; C: performing a first drying on the green body after the green body was decorated with the pattern of step B; D: embellishing the green body with dry particles by spreading the dry particle ink on the surface of the green body after the first drying of step C; then, performing a second drying; E: spraying a protective glaze on the surface of the green body after the second drying of step D; and F: firing the green body after the green body was sprayed with the protective glaze of step E to produce the ceramic tile, the ceramic tile was decorated with the dry particles and had a three-dimensional pattern.

(63) Before step A, the green body was decorated with line textures by means of a digital material distribution method using mechanical arms.

(64) In step A, the ground coat comprised the following chemical components:

(65) TABLE-US-00021 SiO.sub.2 .sup.68% Al.sub.2O.sub.3 19% Fe.sub.2O.sub.3 0.10% CaO 1.28% MgO 0.6% K.sub.2O 2.0% Na.sub.2O 3.18% TiO.sub.2 0.08% BaO 4.83% ZnO 0.93%.

(66) In step C, a temperature of the first drying was 150? C.; wherein in step D, a quantity of the dry particle ink was 3 kg/m.sup.2; wherein in step D, a temperature of the second drying was 150? C.

(67) In step E, the spraying of the protective glaze was carried out by high-pressure spraying, a pressure of the high-pressure spraying was 20 bar, an amount of the protective glaze sprayed was 100 g/m.sup.2; wherein in step F, the firing was carried out at 1220? C. for 60 min.

(68) In step D, the dry particle ink comprised the following raw materials in parts by weight:

(69) TABLE-US-00022 dry particles 40 parts, a dispersant 10 parts, a viscosity modifier 0.15 parts, a surfactant 0.3 parts, an excipient 5 parts, a solvent 80 parts.

(70) Each part of the dispersant comprised 8 parts of polyethylene glycol, 12 parts of polyacrylamide, and 5 parts of polyacrylate; each part of the viscosity modifier comprised 30 parts of acrylic resin, 10 parts of polyethylene glycol methyl ether, and 10 parts of ethanol; the surfactant was ethoxylated fatty acid sorbitan ester.

(71) Each part of the excipient comprised 1.5 parts of a pH regulator, 2 parts of a dryer, and 1.5 parts of a preservative; the pH regulator was ammonia water; the dryer was a mixture consisting of ethanol and isopropanol at a weight ratio of 1:4; the preservative was N-(2-hydroxy propyl) aminomethanol; each part of the solvent was a mixture consisting of ethylene glycol butyl ether acetate, dipropylene glycol dimethyl ether, and propylene glycol methyl ether at a weight ratio of 4:1:2.5.

(72) In step E, the protective glaze was a matte transparent protective glaze, the matte transparent protective glaze comprised the following raw materials in pails by weight:

(73) TABLE-US-00023 calcined zinc oxide 6 parts, barium carbonate 8 parts, potash feldspar 20 parts, a frit 45 parts, calcined alumina 10 parts, burnt talc 14 parts, dolomite 5 parts, kaolin 8 parts, an ultrafine quartz powder 3 parts.

(74) The frit comprised the following chemical components:

(75) TABLE-US-00024 SiO.sub.2 46.5% Al.sub.2O.sub.3 19.41% Fe.sub.2O.sub.3 0.05% CaO 2.35% MgO 0.75% K.sub.2O 1.8% Na.sub.2O 4.5% TiO.sub.2 0.2% B.sub.2O.sub.3 0.04% BaO 15.0% ZnO 6.0% SrO 3.4%.

(76) A ceramic tile decorated with dry particles prepared by the method above, wherein the ceramic tile decorated with dry particles comprised, from bottom to top, a green body layer, a ground coat layer, a pattern layer, a dry particle ink layer and a protective glaze layer; a thickness of the ground coat layer was 0.05-0.2 mm, a thickness of the pattern layer was 0.05-0.1 mm, a thickness of the dry particle ink layer was 0.5-1 mm, and a thickness of the protective glaze layer was 0.02-0.03 mm.

Comparative Example 1 (Using a Common Process of Coating GlueSpreading Dry Particles)

(77) A method for manufacturing a ceramic tile decorated with a dry particle ink, wherein the method comprised A: glazing a surface of a green body with a ground coat; B: maintaining a temperature of the green body at 50? Cafter the green body was glazed with the ground coat of step A; then, decorating a surface of the ground coat of the green body to form a pattern; C: performing a first drying on the green body after the green body was decorated with the pattern of step B; D: spraying glue on the surface of the green body after the first drying of step C; E: embellishing the green body with dry particles by spreading the dry particle ink on the surface of the green body after spraying the glue of step D; then, performing a second drying; and F: firing the green body after the second drying of step E to produce the ceramic tile decorated with the dry particles.

(78) Before step A, the green body was decorated with line textures by means of a digital material distribution method using mechanical arms.

(79) In step A, the ground coat comprised the following chemical components:

(80) TABLE-US-00025 SiO.sub.2 .sup.65% Al.sub.2O.sub.3 .sup.20% Fe.sub.2O.sub.3 0.12% CaO 1.31% MgO 0.64% K.sub.2O 2.4% Na.sub.2O 3.21% TiO.sub.2 0.10% ZrO.sub.2 1.5% BaO 4.82% ZnO 0.90%.

(81) In step C, a temperature of the first drying was 135? C.; wherein in step F, a temperature of the firing was 1200? C. for 70 min.

Comparative Example 2 (Without the Protective Glaze on the Basis of Example 3)

(82) A method for manufacturing a ceramic tile decorated with a dry particle ink, wherein the method comprised A: glazing a surface of a green body with a ground coat; B: maintaining a temperature of the green body at 50? Cafter the green body was glazed with the ground coat of step A; then, decorating a surface of the ground coat of the green body to form a pattern; C: performing a first drying on the green body after the green body was decorated with the pattern of step B; D: embellishing the green body with dry particles by spreading the dry particle ink on the surface of the green body after the first drying of step C; then, performing a second drying; and E: firing the green body after the second drying of step D to produce the ceramic tile, the ceramic tile was decorated with the dry particles and had a three-dimensional pattern.

(83) Before step A, the green body was decorated with line textures by means of a digital material distribution method using mechanical arms.

(84) In step A, the ground coat comprised the following chemical components:

(85) TABLE-US-00026 SiO.sub.2 .sup.65% Al.sub.2O.sub.3 .sup.20% Fe.sub.2O.sub.3 0.12% CaO 1.31% MgO 0.64% K.sub.2O 2.4% Na.sub.2O 3.21% TiO.sub.2 0.10% ZrO.sub.2 1.5% BaO 4.82% ZnO 0.90%.

(86) In step C, a temperature of the first drying was 135? C.; wherein in step D, a quantity of the dry particle ink was 2.5 kg/m.sup.2; wherein in step D, a temperature of the second drying was 135? C.

(87) In step D, the dry particle ink comprised the following raw materials in parts by weight:

(88) TABLE-US-00027 dry particles 35 parts, a dispersant 8 parts, a viscosity modifier 0.10 parts, a surfactant 0.25 parts, an excipient 3.5 parts, a solvent 70 parts.

(89) Each part of the dispersant comprised 5 parts of polyethylene glycol, 11 parts of polyacrylamide, and 3.5 parts of polyacrylate; each part of the viscosity modifier comprised 25 parts of acrylic resin, 8 parts of polyethylene glycol methyl ether, and 8 parts of ethanol; the surfactant was fatty acid polyoxyethylene ester.

(90) Each part of the excipient comprised 1 part of a pH regulator, 1.5 parts of a dryer, and 0.8 parts of a preservative; the pH regulator was triethanolamine; the dryer was a mixture consisting of ethanol and isopropanol at a weight ratio of 1:3.5; the preservative was 2,2-dihydroxy-5,5-dichlorodiphenylmethane; each part of the solvent was a mixture consisting of ethylene glycol butyl ether acetate, dipropylene glycol dimethyl ether, and propylene glycol methyl ether at a weight ratio of 3.5:1:2.0.

(91) A ceramic tile decorated with dry particles prepared by the method above, wherein the ceramic tile decorated with dry particles comprised, from bottom to top, a green body layer, a ground coat layer, a pattern layer, and a dry particle ink layer; a thickness of the ground coat layer was 0.05-0.2 mm, a thickness of the pattern layer was 0.05-0.1 mm, and a thickness of the dry particle ink layer was 0.5-1 mm.

Comparative Example 3 (On the Basis of Example 3, Dry Only Once Before Decorating With Dry Particles, and Do Not Dry After Decorating With Dry Particles)

(92) A method for manufacturing a ceramic tile decorated with a dry particle ink, wherein the method comprised A: glazing a surface of a green body with a ground coat; B: maintaining a temperature of the green body at 50? Cafter the green body was glazed with the ground coat of step A; then, decorating a surface of the ground coat of the green body to form a pattern; C: drying the green body after the green body was decorated with the pattern of step B; D: embellishing the green body with dry particles by spreading the dry particle ink on the surface of the green body after the drying of step C; E: spraying a protective glaze on the surface of the green body after the embellishing of step D; and F: firing the green body after the green body was sprayed with the protective glaze of step E to produce the ceramic tile, the ceramic tile was decorated with the dry particles and had a three-dimensional pattern.

(93) Before step A, the green body was decorated with line textures by means of a digital material distribution method using mechanical arms.

(94) In step A, the ground coat comprised the following chemical components:

(95) TABLE-US-00028 SiO.sub.2 .sup.65% Al.sub.2O.sub.3 .sup.20% Fe.sub.2O.sub.3 0.12% CaO 1.31% MgO 0.64% K.sub.2O 2.4% Na.sub.2O 3.21% TiO.sub.2 0.10% ZrO.sub.2 1.5% BaO 4.82% ZnO 0.90%.

(96) In step C, a temperature of the first drying was 135? C.; wherein in step D, a quantity of the dry particle ink was 2.5 kg/m.sup.2.

(97) In step E, the spraying of the protective glaze was carried out by high-pressure spraying, a pressure of the high-pressure spraying was 15 bar, an amount of the protective glaze sprayed was 85 g/m.sup.2; wherein in step F, the firing was carried out at 1200? C. for 70 min.

(98) In step D, the dry particle ink comprised the following raw materials in parts by weight:

(99) TABLE-US-00029 dry particles 35 parts, a dispersant 8 parts, a viscosity modifier 0.10 parts, a surfactant 0.25 parts, an excipient 3.5 parts, a solvent 70 parts.

(100) Each part of the dispersant comprised 5 parts of polyethylene glycol, 11 parts of polyacrylamide, and 3.5 parts of polyacrylate; each part of the viscosity modifier comprised 25 parts of acrylic resin, 8 parts of polyethylene glycol methyl ether, and 8 parts of ethanol; the surfactant was fatty acid polyoxyethylene ester.

(101) Each part of the excipient comprised 1 part of a pH regulator, 1.5 parts of a dryer, and 0.8 parts of a preservative; the pH regulator was triethanolamine; the dryer was a mixture consisting of ethanol and isopropanol at a weight ratio of 1:3.5; the preservative was 2,2-dihydroxy-5,5-dichlorodiphenylmethane; each part of the solvent was a mixture consisting of ethylene glycol butyl ether acetate, dipropylene glycol dimethyl ether, and propylene glycol methyl ether at a weight ratio of 3.5:1:2.0.

(102) In step E, the protective glaze was a matte transparent protective glaze, the matte transparent protective glaze comprised the following aw materials in parts by weight:

(103) TABLE-US-00030 calcined zinc oxide 5.5 parts, barium carbonate 7 parts, potash feldspar 18 parts, a frit 40 parts, calcined alumina 8 parts, burnt talc 12 parts, dolomite 3 parts, kaolin 7 parts, an ultrafine quartz powder 2 parts.

(104) The frit comprised the following chemical components:

(105) TABLE-US-00031 SiO.sub.2 45.75% Al.sub.2O.sub.3 19.05% Fe.sub.2O.sub.3 0.08% CaO 2.51% MgO 0.95% K.sub.2O 1.91% Na.sub.2O 4.67% TiO.sub.2 0.25% B.sub.2O.sub.3 0.06% BaO 15.19% ZnO 6.18% SrO 3.40%.

(106) A ceramic tile decorated with dry particles prepared by the method above, wherein the ceramic tile decorated with dry particles comprised, from bottom to top, a green body layer, a ground coat layer, a pattern layer, a dry particle ink layer and a protective glaze layer; a thickness of the ground coat layer was 0.05-0.2 mm, a thickness of the pattern layer was 0.05-0.1 mm, a thickness of the dry particle ink layer was 0.2-0.5 mm, and a thickness of the protective glaze layer was 0.02-0.03 mm.

Comparative Example 4 (The Protective Glaze Was a Conventional Protective Glaze That Was Commercially Available)

(107) The difference between this example and the example 3 above lay in:

(108) In step E, the protective glaze was a conventional protective glaze that was commercially available.

(109) The ceramic tiles decorated with dry particles prepared in examples 1-5 above and comparative examples 1-4 were tested for properties such as hardness, wear resistance, glossiness, and interlayer adhesion. The test results were as follows:

(110) TABLE-US-00032 Adhesion grade of Mohs Grade of wear dry particle hardness resistance Glossiness layer Example 1 >7 4 8? 0 Example 2 >7 5 7? 0 Example 3 >7 5 5? 0 Example 4 >7 4 6? 0 Example 5 >7 4 8? 0 Comparative 6.0 2 11? 2 example 1 Comparative 6.0 3 12? 1 example 2 Comparative 5.0 2 8? 1 example 3 Comparative 6.0 3 10? 1 example 4

(111) Wherein, the grade of wear resistance was tested according to a test method of GB/T 3810.7-2016 Standard, and the degree of surface wear traces of samples after grinding at a specific grinding speed was observed. The grade of wear resistance is divided into 0-5 grades, and specific grades are as follows:

(112) TABLE-US-00033 The number of grinding revolutions with visible Grade abrasion 0 100 1 150 2 600 3 750, 1500 4 2100, 6000, 12000 5 >12000

(113) The adhesion grade of the dry particle layer was tested according to a cross-cut test method of GB/T9286-98 Standard, and shedding of the dry particle layer of the test sample was observed. The adhesion grade of the dry particle layer is divided into 0-5 grades, and specific grades are as follows:

(114) TABLE-US-00034 Grade Description of situation 0 Edges are completely smooth, and there is no shedding. 1 There is shedding at an intersection of the cross-cut incision and/or an edge of the incision, but the effect of the cross-cut area is obviously not more than 5%. 2 There is shedding at an intersection of the cross-cut incision and/or an edge of the incision; an affected cross-cut area is obviously larger than 5%, but obviously not larger than 15%. 3 Part or all of a cutting edge is peeled off as large pieces, and/or partly or completely peeled off on different parts of each; an affected cross-cut area is obviously larger than 15%, but obviously not larger than 35%. 4 There are large fragments falling off along the edge of the incision, and/or partial or complete shedding appears in some squares; an affected cross-cut area is obviously larger than 35%, but obviously not larger than 65%. 5 A peeling degree exceeds 4 grades.

(115) According to the test data above, the ceramic tiles made by the disclosure had clear patterns, distinct layers, low glaze glossiness, good non-slip effects, obvious senses of dry particles, strong three-dimensional effects, rich colors, high hardness, high dry particle adhesion, and stable physical and chemical properties.

(116) In comparative example 1, instead of using the dry particle ink of the present disclosure to prepare a dry particle layer, the common spreading process of dry particles on the market was adopted, and the dry particles were spread directly after the glue was spread on the green body. Compared with the ceramic tile prepared in each example of the present disclosure, the surface of the ceramic tile produced in comparative example 1 had lower wear resistance, a wear resistance grade of 2, lower dry particle adhesion, a dry particle layer adhesion grade of 2, slightly higher glossiness (11?), lower slip resistance, a lower dry particle sense, and slightly lower hardness (6.0). This showed that, by spraying the dry particle ink on the surface of the green body of the ceramic tile, the jet printing can be carried out on a designated position on the surface of a green body, so that the texture sprayed can accurately correspond to the pattern-decorated texture, and the distribution uniformity and adhesion of dry particles on the surface of the green body were improved. And the first drying was carried out after the pattern decoration, so that the ink can be fully dried and formed. This prevented the subsequent spreading of the dry particles from causing fuzzy and chaotic pattern ink to undried ink, and improved the uniformity and adhesion of dry particles on the surface of the green body. Furthermore, after the dry particle ink was sprayed, the second drying process was carried out, which can initially heat the green body sprayed and printed with the dry particle ink. This can also avoid the phenomena of cracked bricks and exploded billets, which were caused by rapid firing of the green body sprayed and printed with dry particle ink during the subsequent firing process, and improve the adhesion and hardness of the dry particle layer. It can make the green body of the ceramic tile prepared and the dry particles form a stable bonding layer of body-particle-glaze. The ceramic tile of the present disclosure had an obvious sense of sand, a strong three-dimensional effect, a clear pattern, rich colors, high hardness, high adhesion of the dry particle layer, a difficulty of shedding, high surface wear resistance, low glossiness, and a good non-slip effect.

(117) Compared with example 3, in comparative example 2, the protective glaze was not sprayed at the end of the process, and the ceramic tile produced had lower surface wear resistance, a wear resistance grade of 2, lower dry particle adhesion (Grade 1), higher glossiness (12?), lower slip resistance, a lower dry particle sense, and slightly lower hardness (6.0). This showed that by spraying the protective glaze on the surface of the body after the dry particles was spread, and strictly controlling the spraying pressure and the amount of the protective glaze, the present disclosure can protect the dry particles and improve the adhesion of dry particles on the surface of the green body. This can avoid causing the dry particles to adhere to the kiln wall or roof as a result of the dry particles being blown away or suctioned away, thereby preventing the product from ash contamination, limestone caves, pinholes, etc. It can also make the green body of the ceramic tile and the dry particles form a stable bonding layer of body-glue-particle-glaze, thereby the ceramic tile had an obvious sense of sand, a strong three-dimensional effect, a clear pattern, rich colors, high hardness, high adhesion of the dry particle layer, a difficulty of shedding, high surface wear resistance, low glossiness, and a good non-slip effect.

(118) In the process of comparative example 3, compared with Example 3, drying was only performed once before spraying the dry particle ink, and there was no second drying after spraying the dry particle ink. The surface of the ceramic tile produced had lower wear resistance, a wear resistance grade of 2, lower dry particle adhesion (grade 1), higher glossiness (8?), lower slip resistance, a lower dry particle sense, and slightly lower hardness (5.0). This showed that by performing the second drying process after spraying the dry particle ink, the present disclosure can initially heat the green body sprayed and printed with the dry particle ink. This can also avoid the phenomena of cracked bricks and exploded billets, which are caused by rapid firing of the green body sprayed and printed with dry particle ink during the subsequent firing process, and improve the adhesion and hardness of the dry particle layer. It can make the green body of the ceramic tile prepared and the dry particles form a stable bonding layer of body-particle-glaze. The ceramic tile of the present disclosure had an obvious sense of sand, a strong three-dimensional effect, a clear pattern, rich colors, high hardness, high adhesion of the dry particle layer, a difficulty of shedding, high surface wear resistance, low glossiness, and a good non-slip effect.

(119) Compared with example 3, in comparative example 4, the protective glaze used in the process was a commercially available conventional protective glaze instead of the raw material formula of the protective glaze of the present disclosure; the ceramic tile produced had lower surface wear resistance, a wear resistance grade of 3, lower dry particle adhesion (Grade 1), higher glossiness (10?), lower slip resistance, a lower dry particle sense, and slightly lower hardness (6.0). This showed that spraying the protective glaze of the present disclosure can protect the dry particles to ensure that the dry particles are not blown off or suctioned off during the kiln firing process. It can also improve the adhesion of the dry particles on the surface of the green body, avoid causing the dry particles to adhere to the kiln wall or roof due to the dry particles being suctioned away, thereby preventing the product from ash contamination, limestone caves, pinholes, etc. At the same time, it can improve the wear resistance of the ceramic tile surface, reduce its glossiness, and have the effect of matte frosting. It can also make the green body of the ceramic tile and the dry particles form a stable bonding layer of body-glue-particle-glaze, thereby the ceramic tile has an obvious sense of sand, a strong three-dimensional effect, a clear pattern, rich colors, high hardness, high adhesion of the dry particle layer, a difficulty of shedding, high surface wear resistance, low glossiness, and a good non-slip effect.

(120) The descriptions above are only the preferred examples of the present disclosure, and the specific examples above do not limit the present disclosure. Various variations and modifications can occur within the scope of the technical idea of the present disclosure; all embellishments, modifications or equivalent replacements made by those of ordinary skill in the art according to the descriptions above fall within the protection scope of the present disclosure.